Automatic separator or shaker with electromagnetic vibrator apparatus

ABSTRACT

A vibratory separator (in one aspect, a shale shaker) and methods for using it, the separator in certain aspects having a base, a basket movably mounted on the base, screen apparatus on the basket, material flowing onto the screen apparatus for treatment, at least a portion of the screen apparatus not inclined downhill (e.g. said portion horizontal or uphill), electromagnetic vibratory apparatus connected to the basket for vibrating the basket and the screen apparatus, driving apparatus for driving the electromagnetic vibratory apparatus, and control apparatus (on-site and/or remote) for controlling the driving apparatus and the electromagnetic vibratory apparatus; the material, in one aspect, being drilling fluid material with solids therein.

RELATED APPLICATIONS

This is: a continuation-in-part of U.S. application Ser. No. 11/096,192filed Mar. 31, 2005 which is a continuation-in-part of U.S. applicationSer. No. 10/949,882 filed Sep. 25, 2004; a continuation-in-part of U.S.application Ser. No. 10/835,256 filed Apr. 29, 2004; acontinuation-in-part of U.S. Ser. No. 10/512,372 filed Oct. 25, 2004which claims priority from U.S. Ser. No. 10/134,027 filed Apr. 26, 2002and Application Ser. No. PCT/IB03/01031 filed Mar. 12, 2003; and acontinuation-in-part of U.S. Ser. No. 10/373,216 filed Feb. 24, 2003which claims priority from U.S. Application Ser. No. 60/424,262 filedNov. 6, 2002—all of which are incorporated fully herein and with respectto all of which the present invention claims priority under the PatentLaws.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to vibratory separators and shale shakers; tosuch separators and shakers with electromagnetic vibratory apparatusesfor use with shakers or separators that separate fluid and/or whichemploy one or more screens or screen assemblies inclined uphill and/orare generally horizontal; apparatuses and methods for sensing variousparameters related to the use of separators and shakers, including, butnot limited to, fluid levels in such separators; and to apparatuses andmethods for adjusting such levels and for adjusting the extent of abeach area on a screen.

2. Description of Related Art

In many prior art vibratory separators and shale shakers a pool or massof fluid or material is formed on top of one or more screens or screenassemblies which are used to filter material introduced to the separatoror shaker. The depth of this fluid or material can affect efficientoperation of the separator or shaker. Fluid or material that is too deepmay not be adequately filtered. Fluid or material that is too shallowmay flow across a screen too quickly or without sufficient weight to befiltered adequately.

Shale shakers assist in maintaining certain desired properties ofdrilling fluid by using vibrating screens to remove certain largeparticles while allowing certain smaller particles to remain in thefluid. The large undesirable particles may include drilling cuttings anddebris picked up in the drilling process. The smaller particles mayinclude drilling fluid additives that are required for maintainingdesired drilling fluid density and viscosity. The screens on theseshakers have a limited life, and can be expensive and time consuming toreplace. The shaker is turned off and, preferably, rinsed clean prior toscreen replacement.

One factor in screen life is how well the beach area is maintained.“Beach” area is the distance from a fluid-dry interface-with-fluid lineon a final screen to the end of the screen. Thus, a zero beach lengthdescribes a shaker operating with drilling fluid covering the entirescreen area of the final screen and running over to discharge. This canbe costly due to the loss of drilling fluid which flows off, rather thanthrough, a screen. A beach length of 20″ in certain shakers indicates ashaker operating fairly dry, with the last sections of screenpotentially vibrating against completely dry particles. Such dryparticles vibrating on the beach of the last screen can tear holes inthe screen and shorten the screen life. The beach length is affected byvariables such as fluid flow rates and drilling fluid propertiesincluding viscosity, density, temperature, and solids content.

In many prior art separators and shakers tilting or raising mechanismsare provided to adjust the angle of screen(s) with respect to thehorizontal. For example, a prior art shaker S (shown in FIG. 1) has atilting mechanism which permits a screen-containing basket to be tiltedaround a pivot point P up to 5° from the horizontal.

U.S. Pat. No. 4,082,657 discloses a separator apparatus which hasindividual height adjustable mounting structures for each screen unitwhich permit adjustment of the screen unit angle with respect to thehorizontal.

U.S. Pat. No. 6,575,304 B2 discloses an hydraulic ram apparatus beneatha screen body which is used to adjust the angle of incline of the screenbody.

In many prior art systems, a determination of the level of material orfluid on a screen or screen assembly of a separator or shaker is donevisually and then adjustments of screen incline angle or of screensupport incline angle are done manually.

There has long been a need, recognized by the present inventors, toprovide an efficient and accurate measurement of the depth of fluid ormaterial on a screen or screen assembly of a vibratory separator orshale shaker. There has long been a need, recognized by the presentinventors, for such separators and shakers with accurate adjustment ofsuch depth based on measurement thereof. There has long been a need,recognized by the present inventors, for a shale shaker or vibratoryseparator with screen pool depth adjustability to efficiently adjustlast-screen beach extent to enhance screen efficiency and to prolongscreen life.

SUMMARY OF THE PRESENT INVENTION

The present invention, in certain embodiments, discloses a shale shakeror vibratory separator with a base; a basket or other screen mountingstructure movably mounted on the base for supporting screen apparatusfor treating material introduced at a first end of the basket into thevibratory separator; a screen, screens, screen assembly, or screenassemblies on the basket either inclined uphill or flat and/or theseparator or shaker for separating fluid from an input feed; and atleast one electromagnetic vibratory apparatus for vibrating the basketor other structure to vibrate the screen, etc.

The present invention, in certain embodiments, discloses a shale shakeror vibratory separator with a base; a basket movably mounted on the baseand for supporting screen apparatus for treating material introduced ata first end of the basket into the vibratory separator, the basket on abase and the first end pivotable with respect thereto, the basket havinga second end spaced apart from the first end, material exiting thebasket at the second end; vibratory apparatus connected to the basketfor vibrating the basket; screen apparatus supported by the basket, thematerial flowing onto the screen apparatus for treatment; angleadjustment apparatus connected to the basket for adjusting angle of thebasket by pivoting the basket's first end; sensor apparatus connected tothe vibratory separator for sensing a parameter indicative of basketangle and for providing a signal corresponding to said basket angle;control apparatus for receiving signals from the sensor apparatus andfor controlling basket angle based on said signals; and the angleadjustment apparatus including movement apparatus for moving the secondend up and down to change basket angle, the movement apparatuscontrolled by the control apparatus.

The present invention, in certain aspects, discloses a vibratoryseparator with a base; a basket movably mounted on the base and forsupporting screen apparatus for treating material introduced into thevibratory separator, the basket on a base and pivotable with respectthereto; vibratory apparatus connected to the basket for vibrating thebasket; screen apparatus supported by the basket, the material flowingonto the screen apparatus for treatment; angle adjustment apparatusconnected to the basket for adjusting angle of the basket; sensorapparatus for sensing a parameter indicative of basket angle and forproviding a signal corresponding to said basket angle; control apparatusfor receiving signals from the sensor apparatus and for controllingbasket angle based on said signals; the angle adjustment apparatusincluding a rocker arm assembly with a first end and a second end, thefirst end pivotably mounted to the base adjacent and beneath a materialinput area of the vibratory separator and the second adjacent andbeneath a material exit end of the vibratory separator; and the angleadjustment apparatus including movement apparatus with a part thereof incontact with the second end of the rocker arm assembly for moving thesecond end up and down to change basket angle, the movement apparatuscontrolled by the control apparatus.

The present invention discloses, in certain embodiments, beachadjustment apparatus for adjusting extent of a beach on a screen of avibratory separator, the screen mounted to a vibratable basket of thevibratory separator, the beach adjustment apparatus having anend-pivotable basket support for supporting the basket, theend-pivotable basket support pivotable at a pivot end thereof, the endpivotable basket support having a second end spaced-apart from the pivotend, the second end positionable near an exit end of a vibratoryseparator, apparatus for pivoting the end-pivotable basket support atits pivot end, and the apparatus for pivoting the end-pivotable basketsupport including movement apparatus for moving the second end of theend-pivotable basket support for facilitating pivoting movement of theend-pivotable basket support to raise and lower the second end to adjustthe extent of the beach.

The present invention, in certain embodiments, teaches a vibratoryseparator (in one particular aspect, a shale shaker) which has sensingapparatus for sensing parameters indicative of the level of fluid ormaterial on a screen or screen assembly supported by the separator and,therefore, for indicating the extent of a beach area on the screen orscreen assembly. In one aspect, a screen or screen assembly itself (or ascreen on holding structure) is able to be inclined to a desired angleto adjust the extent of a beach area adjacent an exit end of a screen. Abeach area is an area adjacent a screen's exit end with two boundarysides—a first side (or rear side) is the side of a pool of material onthe screen (analogous to the seashore) and the second side or front sideis at or near the exit end of the screen. It is important in somesystems to maintain a beach area of desired extent which is sufficientlylarge so that the pool does not extend to or beyond the screen's exitend—which would result in some material not being treated (filtered,separated) by the screen and simply flowing off the end of the screen.It is also important in some systems to insure that the beach area isnot too large which could adversely affect screening efficiency andeffectiveness.

In certain aspects, such a separator also has adjustment apparatus(powered electrically, hydraulically, or pneumatically) for receivinginformation from one or more sensing apparatuses regarding distance tofluid or material at a certain location on a screen or screen assembly(which corresponds to pool depth at the location) and for then adjustingincline angle of the screen or screen assembly to adjust and maintainthe extent of a beach area adjacent an exit end of a screen.

In certain aspects, any suitable basket pivot point is used from abasket center to a basket end. In one particular aspect a basket forsupporting a screen or screen assembly is positioned and configured sothat it pivots at a pivot point relatively near one of its ends; and, inone particular aspect, such a pivot is beneath a rear line which is therear boundary of a desired beach area (“rear” meaning the beach boundaryfarthest away from the exit end of a screen).

The present invention, in certain aspects, discloses a shale shaker orvibratory separator with a screen support or basket for supportingscreen apparatus for treating material introduced into the vibratoryseparator, the basket on a base and pivotable with respect thereto;vibratory apparatus connected to the basket for vibrating the basket;screen apparatus supported by the basket, the material flowing onto thescreen apparatus and forming a pool on the screen apparatus, and a beachon the screen apparatus adjacent the pool; measurement sensor apparatusconnected to the vibratory separator and positioned above the screenapparatus for measuring a distance from the measurement sensor apparatusto a top surface of the pool, the measurement sensor apparatus includinga signal production portion for producing signals indicative of saiddistance and for transmitting said signals; a control system forcontrolling and in communication with the measurement sensor apparatusfor receiving signals from the measurement sensor apparatus indicativeof said distance and for processing said signals to calculate a pooldepth corresponding to said distance, said pool depth related to alocation of an edge of said pool adjacent said beach; and angleadjustment apparatus connected to the basket and controlled by thecontrol system for adjusting angle of the basket, thereby adjustingextent of the beach.

In one particular aspect, a shale shaker according to the presentinvention consists of a vibrating basket which supports multiplescreens. Drilling fluid is directed to flow over the screens from a weirtank. As fluid flows over the screens, drilling fluid and smallerparticles pass through the screens and are returned to the drillingfluid system. The larger particles and pieces remain on top of thescreens, and vibratory action moves them off an end of the shaker.Within the shaker, the angle at which the basket sits can be changed tomaintain the desired beach area. One or more ultrasonic transducersensor measuring apparatuses mounted above a screen or screens, (in oneaspect above the last screen) measures the fluid level on screen(s) oron the last screen. In one particular aspect a single sensor is usedabove the pool above a last screen which is a pool area that is lessturbulent than previous screen areas and, in one aspect, a basket pivotpoint is located beneath a beach's rear line so that the single sensorprovides all needed information to adjust beach extent as desired. Thelevel of the fluid on the screen(s) is related to the rear or innerbeach boundary. A signal from the sensor(s) indicative ofsensor-to-pool-surface distance is sent to a control system, e.g. acomputerized control system, a programmable logic controlled controlsystem, a digital signal processor and/or a microprocessor based controlsystem which interprets the signal and sends a control signal to aheight adjustment apparatus, e.g., but not limited to, a system with adirectional control valve which controls pressurized hydraulic fluidflow to pistons attached via linkages between the shaker base and basketand/or any basket raising apparatus (mechanical, pneumatic, orhydraulic; e.g. but not limited to hydraulically-powered piston/cylinderapparatuses) of the prior art. In certain aspects, multiple distancemeasurements are made and the controller is programmed to average themeasurements. As the basket is raised or lowered, the basket anglechanges. When the beach width is too long, the height adjustmentapparatus decreases the angle of the basket, and when the beach width istoo short, the angle of the basket is increased. Thus, the desired beachextent is automatically maintained. A desired sensor-to-pool-surfacedistance, and thus a desired beach width can be programmed into thecontrol system for a particular separator, shaker, screen, or screenassembly.

In one particular aspect a power system for providing hydraulic fluidunder pressure to apparatus for raising and lowering a basket usesdouble rod hydraulic cylinders so that dual apparatuses on two sides ofa basket operate in unison. One or more sensors may be connected to orover a basket, to a rear tank, to a skid or base, or to a motor tube ormount. In one aspect a fluid reservoir (hydraulic fluid or gas) and/orfluid pump apparatus is part of a vibratory separator system or part ofa shale shaker. In one particular aspect, a skid, base, or support of ashaker or part of a shaker supports a fluid reservoir; and pumpapparatus on the shaker provides fluid to height adjustment apparatus.

In certain aspects a fluid flow sensor is employed on a vibratoryseparator or shale shaker which gives an indication when the flow ofmaterial ceases so that a basket end near a material input point can belowered so that upon recommencement of the material flow the basketangle is such that material does not flow off a last screen's exit endwithout being treated.

In certain aspects the present invention provides a vibratory separator(e.g. but not limited to a shale shaker) with a basket for supportingscreen apparatus for treating material introduced into the vibratoryseparator, the basket on a base and pivotable with respect thereto;vibratory apparatus connected to the basket for vibrating the basket andthe screen apparatus in the basket; screen apparatus supported by thebasket, the material flowing onto the screen apparatus and forming apool on the screen apparatus, and a beach formed on the screen apparatusadjacent the pool; measurement sensor apparatus connected to thevibratory separator and positioned above the screen apparatus formeasuring a distance from the measurement sensor apparatus to a topsurface of the pool, the measurement sensor apparatus including a signalproduction portion for producing signals indicative of said distance andfor transmitting said signals; a control system for controlling and incommunication with the measurement sensor apparatus for receivingsignals from the measurement sensor apparatus indicative of saiddistance and for processing said signals to calculate a pool depthcorresponding to said distance, said pool depth related to a location ofan edge of said pool adjacent said beach; and angle adjustment apparatusconnected to the basket and controlled by the control system foradjusting angle of the basket, thereby adjusting extent of the beach.

What follows are some of, but not all, the objects of this invention. Inaddition to the specific objects stated below for at least certainpreferred embodiments of the invention, there are other objects andpurposes which will be readily apparent to one of skill in this art whohas the benefit of this invention's teachings and disclosures. It is,therefore, an object of at least certain preferred embodiments of thepresent invention to provide new, unique, useful, and nonobvious systemsand methods of their use—all of which are not anticipated by, renderedobvious by, suggested by, or even implied by any of the prior art,either alone or in any possible legal combination; and it is, therefore,an object of at least certain preferred embodiments of the presentinvention to provide:

New, useful, unique, efficient, non-obvious vibratory separators andshale shakers and methods of their use and such separators and shakerswith electromagnetic vibratory apparatus for vibrating a screen,screens, screen assembly, or screen assemblies in the separator orshaker;

Such separators and shakers with one or more energizable identificationapparatuses or devices (e.g., but not limited to, SAW's and/or RFIDT's)in or on the shaker, separator, parts thereof, screen(s), and/orvibration apparatus(es);

Such separators and shakers with one or more sensing apparatuses forsensing parameters indicative of the depth of fluid or material onscreen(s) or screen assemblies supported by the separator or shaker,which depth is related to the extent of a beach area on the screen(s) orscreen assemblies;

Such separators or shakers with a screen support which is pivotable ator near one of its ends for screen inclination angle adjustment therebyadjusting beach area;

Such separators or shakers with adjustment apparatus for adjustingscreen inclination angle based on information received from the sensingapparatus or apparatuses;

Such separators or shakers with sensor(s) to sensesensor-to-pool-surface distance on screen(s) and to automatically adjustsaid distance to maintain a desired beach extent on a screen; and, inone aspect, on a last or material-exit screen; and, in one aspect, asingle sensor which, in certain embodiments, is located above a basketpivot point;

Such separators or shakers with material flow sensing apparatus so thatbasket angle can be adjusted and readjusted depending on the materialflow status; and

New, useful, unique, efficient, non-obvious beach adjustment apparatusfor adjusting beach extent on a screen of a vibratory separator or shakeshaker.

Certain embodiments of this invention are not limited to any particularindividual feature disclosed here, but include combinations of themdistinguished from the prior art in their structures and functions.Features of the invention have been broadly described so that thedetailed descriptions that follow may be better understood, and in orderthat the contributions of this invention to the arts may be betterappreciated. There are, of course, additional aspects of the inventiondescribed below and which may be included in the subject matter of theclaims to this invention. Those skilled in the art who have the benefitof this invention, its teachings, and suggestions will appreciate thatthe conceptions of this disclosure may be used as a creative basis fordesigning other structures, methods and systems for carrying out andpracticing the present invention. The claims of this invention are to beread to include any legally equivalent devices or methods which do notdepart from the spirit and scope of the present invention.

The present invention recognizes and addresses the previously-mentionedproblems and long-felt needs and provides a solution to those problemsand a satisfactory meeting of those needs in its various possibleembodiments and equivalents thereof. To one of skill in this art who hasthe benefits of this invention's realizations, teachings, disclosures,and suggestions, other purposes and advantages will be appreciated fromthe following description of preferred embodiments, given for thepurpose of disclosure, when taken in conjunction with the accompanyingdrawings. The detail in these descriptions is not intended to thwartthis patent's object to claim this invention no matter how others maylater disguise it by variations in form or additions of furtherimprovements.

The Abstract that is part hereof is to enable the U.S. Patent andTrademark Office and the public generally, and scientists, engineers,researchers, and practitioners in the art who are not familiar withpatent terms or legal terms of phraseology to determine quickly from acursory inspection or review the nature and general area of thedisclosure of this invention. The Abstract is neither intended to definethe invention, which is done by the claims, nor is it intended to belimiting of the scope of the invention in any way.

It will be understood that the various embodiments of the presentinvention may include one, some, or all of the disclosed, described,and/or enumerated improvements and/or technical advantages and/orelements in claims to this invention.

DESCRIPTION OF THE DRAWINGS

A more particular description of embodiments of the invention brieflysummarized above may be had by references to the embodiments which areshown in the drawings which form a part of this specification. Thesedrawings illustrate certain preferred embodiments and are not to be usedto improperly limit the scope of the invention which may have otherequally effective or equivalent embodiments.

FIG. 1 is a schematic side view of a prior art shale shaker.

FIG. 2A is a schematic view of a system according to the presentinvention.

FIG. 2B is a schematic side view of shale shaker apparatus of the systemof FIG. 2A.

FIG. 3 is a side schematic view of a system according to the presentinvention.

FIG. 4 is a side schematic view of a system according to the presentinvention.

FIG. 5A is a schematic view of a prior art shale shaker.

FIG. 5B is a side schematic view of a system according to the presentinvention.

FIG. 6 is a side schematic view of a system according to the presentinvention.

FIG. 7 is a side schematic view of screen assemblies according to thepresent invention.

FIG. 8A is a side schematic view of a screen assembly according to thepresent invention.

FIG. 8B is an end view of a screen assembly of FIG. 8A.

FIG. 8C is an end view of a screen assembly of FIG. 8A.

FIG. 9 is an end view of a system according to the present invention.

FIG. 10A is a side view of a shale shaker according to the presentinvention.

FIG. 10B is a side cross-section view of the shaker of FIG. 10A.

FIG. 10C is a side cross-section view which shows the shaker of FIG. 10Awith its basket tilted.

FIG. 10D is a front end view of the shaker of FIG. 10A.

FIG. 10E is a schematic diagram of a control apparatus for the shaker ofFIG. 10A.

FIG. 10F is a top schematic view of a vibratory separator according tothe present invention.

FIG. 11A is a side end view of a shale shaker according to the presentinvention.

FIG. 11B is a partial cross-section view of the shale shaker of FIG.11A.

FIG. 11C is a partial cross-section view of the shale shaker of FIG.11A.

FIG. 11D is an end view of the shale shaker of FIG. 11A.

FIG. 12A is a side view of a rocker arm assembly of the shale shaker ofFIG. 11A.

FIG. 12B is a top view of the rocker arm assembly of FIG. 12A.

FIG. 13 is a schematic view of a control system according to the presentinvention for a vibratory separator according to the present invention.

FIG. 14 is a schematic view of a system according to the presentinvention.

FIG. 15 is a side view of a shale shaker according to the presentinvention.

FIG. 16 is a top view of the shale shaker of FIG. 15.

FIG. 17 is an end view of the shale shaker of FIG. 15.

FIG. 18 is an illustration of a preferred status display for an oilrecovery system showing status for individual rigs and aggregatedworst-case status for geographical areas.

FIG. 19 is an illustration of a preferred status display for an oilrecovery system showing status for individual rigs and aggregatedworst-case status for a smaller geographical area including WesternCanada.

FIG. 20 is an illustration of a preferred status display for an oilrecovery system showing status for individual rigs and panel resultsshowing text descriptions and color-coded status for a single oil rig.

FIG. 21A is an illustration of a preferred status display for an oilrecovery system and a sub status for an individual rig.

FIG. 21B is an illustration of an alternative status display for an oilrecovery system and a sub status for an individual rig.

FIG. 22 is an illustration of a preferred status display for an oilrecovery system and a lower level sub status for an individual rig.

FIG. 23 is an illustration of a preferred status display for an oilrecovery system and a lower level sub status for an individual rig.

FIG. 24 is an alternative tabular status display for an oil recoverysystem.

FIG. 25 is an alternative tabular status display for an oil recoverysystem.

FIG. 26 is an illustration of a preferred health check system reportinghealth checks from an oil rig to a user via satellite.

FIG. 27 is an illustration of a preferred health check system reportinghealth checks of multiple equipments, processes or systems from multipleoil rigs to a multiple users.

FIG. 28 is an illustration of a preferred protocol which defines anevent reporting data structure for data base population and display.

FIG. 29 is a screen display for a system according to the presentinvention.

FIG. 30 is a screen display for a system according to the presentinvention.

FIG. 31 is a screen display for a system according to the presentinvention.

FIG. 32A is a screen display for a system according to the presentinvention.

FIG. 32B is a screen display for a system according to the presentinvention.

FIG. 33 is a side view of a shale shaker according to the presentinvention.

FIG. 34 is a top view of the shale shaker of FIG. 33.

FIG. 35 is an end view of the shale shaker of FIG. 33.

FIG. 36 is a side view of a shaker according to the present invention.

FIG. 37 is a perspective view of a screen assembly according to thepresent invention.

FIG. 38A is a top view of a screen assembly according to the presentinvention.

FIG. 38B is an end view of the screen assembly of FIG. 38A.

FIG. 38C is a side view of the screen assembly of FIG. 38A.

FIG. 38D is a perspective view of part of the screen assembly of FIG.38A.

FIG. 39A is a top view of a screen assembly according to the presentinvention.

FIG. 39B is a top view of a screen assembly according to the presentinvention.

FIG. 39C is an end view of the screen assembly of FIG. 39B.

FIG. 39D is an enlargement of part of the screen assembly shown in FIG.39C.

FIG. 40 is an end view of a screen assembly according to the presentinvention.

FIG. 41A is a top view of a screen assembly according to the presentinvention.

FIG. 41B is an exploded view of the screen assembly of FIG. 41A.

FIG. 41C is an end view of a screen assembly of FIG. 41A.

FIG. 41D is an enlargement of part of the screen assembly of FIG. 41C.

FIG. 41E is an end view of a screen assembly according to the presentinvention.

FIG. 42A is a top view of a screen assembly according to the presentinvention.

FIG. 42B is a section view along line 42B-42B of FIG. 42A.

FIG. 42C is a perspective view of an apparatus according to the presentinvention.

FIG. 42D is a perspective view of an apparatus according to the presentinvention.

FIG. 42E is a perspective view of an apparatus according to the presentinvention.

FIG. 43A is a perspective view of a shale shaker according to thepresent invention.

FIG. 43B is an end view of the shaker of FIG. 43A.

FIG. 43C is a side view of the shaker of FIG. 43A.

FIG. 43D is a top view of the shaker of FIG. 43A.

FIG. 43E is a side view of part of the shaker of FIG. 43A.

FIG. 44A is a side view in cross-section of a shaker according to thepresent invention.

FIG. 44B is a side view in cross-section of a shaker according to thepresent invention.

FIG. 44C is a side view in cross-section of a shaker according to thepresent invention.

DESCRIPTION OF EMBODIMENTS PREFERRED AT THE TIME OF FILING FOR THISPATENT

Referring now to FIGS. 2A and 2B, a drilling system 10 according to thepresent invention includes a rotary bit 12 attached to the lower end ofa length of hollow drill pipe 14 suspended from a drilling derrick (notshown).

The drill pipe 14 and attached drill bit 12 are rotated to cut into thesubsurface formation 16 to form a wellbore 18. The drill pipe 14 passesthrough a wellhead assembly 20 located at the surface. The wellheadassembly 20 controls flow of drilling fluid into the well. During thedrilling of the well, a drilling fluid 22 commonly referred to asdrilling mud is pumped down the interior of the hollow drill pipe 14.The drilling mud exits jets such as jet 24 in drill bit 12 and impingesupon a bottom 26 of the well bore 18. The drilling fluid exiting thejets 24 flushes away from the bottom 26 of the wellbore 18 the cuttingsor particles generated as the drill bit 12 cuts into the earthenformation 16. A stream of drilling mud 22 then carries the cuttings andparticles upward through a well annulus 28 (arrows 29) to the wellhead20. The drilling mud 22 with the particles and cuttings carried orsuspended therein, exits the wellhead 20 at outlet 31 and passes througha conduit 30 to a shaker system according to the present invention whichincludes a shale shaker 32.

In the shaker 32, the drilling mud and particles are deposited upon oneor more screens which are vibrated so that the larger particles aresifted out of the drilling mud and carried off the top of the screen(s).

A liquid portion of the drilling mud along with very fine suspendedparticles exits a first shaker outlet 34 and is received in a mud pit36.

Larger particles 44 which are sifted out of the stream of drilling mudexit a second shaker outlet or trough 38 and are conveyed on a conveyoror slide 40 for deposit into a reserve pit 42 or into storage tanks forhaulage to another location. The drilling mud is pumped from the mud pit36 through a line 46 by a mud pump 50. The mud pump 50 then pumps themud through a discharge line 52 which returns it to the interior bore ofdrill pipe 14.

As shown in FIGS. 2A and 2B the shale shaker 32 has a fluid levelsensing apparatus 60 which is in communication with a control apparatus70. The sensing apparatus 60 senses a distance to a top surface of thedrilling mud 22 on a screen 33 of the shaker 32, which is indicative ofmud depth. Via a signal transmission line 62 (or multiple such lines ifneeded) the sensing apparatus sends a signal to the computer apparatus70 indicative of this distance. The apparatus 70 controls the sensingapparatus 60 via a line 63 (or multiple such lines if needed).

The shale shaker 32 (or a screen supporting basket thereof) is supportedby a first support 37 which has a pivotal connection 39 and by a secondsupport 51 which has a pivotal connection 52 and a movable post 53 whichis selectively movable up and down by moving apparatus 54 to pivot theshale shaker 32 (or its basket alone) on the pivotal connection 39 toaffect the angle of the shaker or basket 32, the depth of drilling fluidbeneath the sensing apparatus 60, and the extent of a beach area on thescreen 33. Via a line 65 the computer apparatus 70 controls a controlapparatus 72 that selectively operates the moving apparatus 54 (whichmay be pneumatically, hydraulically or electrically powered as may beany such apparatus or height adjustment apparatus of any systemaccording to the present invention).

The sensing apparatus 60 may be (and as may be the case for any sensorof any system disclosed herein) any suitable known level and/or distancesensing apparatus including, but not limited to, the following types:electrical, optical, electromagnetic, ultrasonic, acoustic, andpulse-echo, and may be like the level sensing systems disclosed in U.S.Pat. Nos. 6,691,025 B2; 5,793,705; 5,319,972; 6,484,088 B1; 6,062,070;and 5,131,271 (all said patents incorporated fully herein for allpurposes) and the systems referenced, referred to or mentioned in thesepatents. The apparatus 70 may be (and as may be for any system disclosedherein) any suitable computer, computers, computer system,microprocessor-based system and/or programmable logic controller(s).

FIG. 3 shows a shale shaker 100 according to the present invention whichhas a basket 101 vibrated by interconnected vibrating apparatus 107. Thebasket 101 supports three screens 102, 103, 104 for treating materialintroduced onto screen 104 from a tank 106.

An ultrasonic level sensor 110 is connected to the basket 101 andselectively senses the distance to, and, therefore the level of thematerial 114 (e.g., drilling fluid with solids entrained therein) at alocation 116 above the screen 103. A control apparatus 111 controls thesensor 110 via a cable 118 and also, via the cable 118, the sensor 110sends signals to the control apparatus 111 indicative of a measurementof the level at the location 116. In one aspect the control apparatus111 includes suitable apparatus (e.g. like the apparatus 70 describedabove) which calculates the depth at the location 116 and, based onsuitable programming in suitable programming media in the controlapparatus 111, adjusts the inclination of the basket 101 usingadjustment apparatus 112 so that the depth at the location 116 ismaintained at a desired level.

In one aspect the basket 101 is pivotally connected to a support 113 ata pivot point 115. The support 113 is secured to a base 105, as is thetank 106 and adjustment apparatus 112. Fluid and/or solid materialflowing through the screens 102-104 flows down into a receptacle 117.Separated material 108 flows off an exit end of the last screen 102.

FIG. 4 shows a shale shaker 120 according to the present inventionsimilar to the shale shaker 100, FIG. 3 (and like numerals indicate likeparts); but the shale shaker 120 has individual tilting mechanisms 131,132, 133 (each with a respective pivot point 131 a, 132 a, 133 a) eachbeneath a respective screen 121, 122, 123. Levels of drilling fluid 128at various locations on the screens 121-123 can be adjusted byselectively changing the inclination of the screens 121-123. Controlapparatuses 134-136 correspond, respectively, to the mechanisms 131-133.A control system 127 with suitable control apparatus (e.g. like theapparatus 70, FIG. 2B) communicates with the control apparatuses 131-133and also with individual level sensors 124, 125, and 126. Each sensor124-126 senses the level of drilling fluid 128 at, respectively,locations 137, 138 and 139. The control apparatus in one aspect ispre-programmed to maintain the drilling fluid levels at locations137-139 at predetermined levels by monitoring the levels with thesensors 124-126 and adjusting the depths at those locations by pivotingthe screens 121-123 by pivoting the individual tilting mechanisms131-133. Any one or any two of the sensors 124-126 may be deleted andthe corresponding tilting mechanism(s) and associated control(s) may bedeleted.

FIG. 5A shows a prior art shale shaker with a pivot point at or near amid-point of a shaker basket (“fine screening basket”). FIG. 5B shows ashale shaker 150 according to the present invention which has a basketpivot point 161 at or near one end of a basket 160. The shaker 150 has aback tank 151 from which material to be treated flows into a scalpingbasket 170 which removes massive and/or gross size pieces and particlesand from which material then flows down onto screens 153-156. Heightadjustment apparatus 158 (controlled as is any adjustment apparatusdisclosed herein) selectively pivots the basket 160 about the point 161.Vibrating apparatus 157 vibrates the basket 160. Material passingthrough the screens flows into a receptacle 159 on a skid 165.

In one aspect the present invention provides a separator like thatdisclosed in U.S. Pat. No. 4,082,657 (incorporated fully herein for allpurposes); but with improvements according to the present invention. Asshown in FIG. 6 a separating device D according to the present inventionfor separating particulate from a fluid stream includes a frame 210having mounted thereon an inlet tank 211 for receiving a fluid to befiltered or cleaned. Screen units 214 a and 214 b are mounted incascaded alignment on the frame 210 by vibration mount means generallydesignated as 215 a and 215 b which each includes a vibrating means 216mounted therewith for vibrating screen units 214 a and 214 bsimultaneously.

The frame 210 includes first and second side members 210 a (only one isillustrated) which are connected together by a front end connecting rod210 b and a rear connecting rod 210 c. The front and rear connectingrods 210 b and 210 c cooperate with the side members such as 210 a toprovide a generally rectangular form having an opening therethroughthrough which the cleaned fluid stream may pass to a recovery areapositioned therebelow. The side frame members such as 210 a may beI-beams or other suitable frame members for supporting the structure tobe disclosed here.

The inlet tank 211 has connected therewith an inlet line 211 b forreceiving the fluids to be cleaned. In one aspect the screen unit 214 aand 214 b includes a metal frame with screening material thereon.

The screen units are releasably mounted in screen unit mounting assemblysupports 222 and 222 a.

Each screen unit is supported by four adjustable posts 235 (two shown oneach side of each screen; e.g. as described in U.S. Pat. No. 4,082,657).Optionally, interposed between the screen units' supports 222, 222 a arespring mechanisms 233 and 234. Vibratory apparatuses 216 vibrate thescreen units.

A sensor 240 on a support 240 a senses the depth of fluid on the screenunit 214 a and a sensor 242 on a support 242 a senses the depth of fluidon the screen unit 214 b. A control apparatus 250 (like any disclosedherein) is in signal communication with the sensors 240, 242 via cables243, 244. The control apparatus 250 is also in communication via cables247, 248 with control apparatuses 245, 246 which control theheight-adjustable posts 235. The control apparatuses 250, 245, 246 maybe like any control apparatus and/or computer apparatus described above.

FIG. 7 shows three screen assemblies 261, 262, 263 according to thepresent invention which may be used in any system according to thepresent invention in which screen assemblies, screens, or individualscreen supports are tilted or moved to adjust fluid depth at a locationon a screen assembly or screen. Each screen assembly 261-263 has anexpandable member 264 (e.g., but not limited to, an expandable bellowsor seal) which insures that sealing contact is maintained betweenadjacent screen assemblies (or between a screen assembly end and amember on a basket against which a screen assembly end abuts). In oneaspect as shown the expandable members 264 are bellows seals; but it iswithin the scope of this invention for any suitable seal or sealingmaterial to be used which can expand and contract sufficiently tomaintain a seal between adjacent screens.

FIGS. 8A-8C illustrate a screen assembly 265 according to the presentinvention which has a flexible end seal 266 which seals against an endof an adjacent screen 267. The seal 266 is sufficiently wide that itwill seal against the end of the screen assembly 267 when theinclination of the screen assembly 267 is changed (and/or when theinclination of the screen assembly 265 is changed) e.g. in response to asignal from a fluid level sensor above either or both screen assemblies265, 267. Optionally, the screen assembly 267 may also have an end seal264.

FIG. 9 shows a vibratory separator 270 according to the presentinvention with walls 274 and a screen assembly 271 in a crownedconfiguration with fluid 272 to be treated thereon. A fluid level sensor273 connected to a wall 274 of the separator 270 with a connector 275senses fluid level near a center point of the screen assembly 271 (asviewed in FIG. 9). A fluid level sensor 276 senses fluid level near thewall 274. It is within the scope of the present invention to locate oneor more fluid sensors at any point above a screen assembly in avibratory separator or shaker. Optionally, either sensor 273 or 276 maybe deleted.

FIGS. 10A-10D show a shale shaker 300 according to the present inventionwhich is like a King Cobra Shale Shaker commercially available fromVarco International, Inc., but which has improvements according to thepresent invention. The shale shaker 300 has a skid or base 302 on whichis a basket 306 which is vibrated by vibration apparatus 304. From aweir tank 308 fluid, e.g. drilling fluid with drilled cuttings anddebris therein, flows onto a first screen 310 which is supported by ascreen support 310 a connected to the basket 306. Part of the fluid thenflows onto a second screen 311 supported by a screen support 311 aconnected to the basket 306 and then part of the fluid flows onto a lastscreen 312 supported by a screen support 312 a connected to the basket306. Part of the fluid flows off an exit end 312 b of the screen 312onto an optional lower screen 313 which is supported by a screen support313 a connected to the basket 306.

The fluid forms a pool 315 above the screens 310-312. Depending on thefluid, on the fluid viscosity, on the fluid's solids content, on therate of fluid flow, and the through-put of the screens, a beach 316 iscreated at the exit end 312 b of the screen 312. It is desirable tooptimize the extent of this beach 316 and, in certain aspects, it ispreferred that the beach, as viewed in FIG. 10B, be sufficiently largethat no fluid flows untreated off the last screen 312.

An ultrasonic transducer sensor measurement apparatus 320 is connectedto the basket 306 (e.g. to a motor tube 309 and/or such a sensorapparatus 320 b is connected to a weir tank 308) and is, optionally,positioned above the pool 315, e.g. over an entry end 310 b of thescreen 310 or over an entry end 312 c of the screen 312. Such locationsfor the apparatus 320 provide measurement at locations providing thegreatest range of pool depth and therefore, the greatest range foradjusting beach extent; i.e., such a location insures that theapparatuses 320 a and/or 320 b will have a sensor-to-pool-surfacedistance to measure since in most cases there will be fluid at somedepth at this point beneath the apparatus or apparatuses 320. Theapparatuses 320 a and/or 320 b are in communication with a controlapparatus 330. The sensor apparatuses generates a signal indicative ofsensor-to-pool distance which indicates depth of the pool 315 beneaththe sensor apparatus(es). Optionally, either the sensor 320 a or thesensor 320 b is deleted.

The control apparatus 330 (e.g. a computer, PLC, PID controller, orother device with programmable media) selectively controls a controlvalve 336 which allows hydraulic fluid under pressure from a reservoir338 pumped by an hydraulic pump 337 to move to and from two hydrauliccylinder apparatuses (one shown, FIG. 10A) which are on opposite sidesof the shaker 300. A flow control valve 332 controls the flow of fluidinto/out of the pistons and adjusts the rate of stroke in the cylinderapparatuses 333, 334 and a flow control valve 335 limits the flow offluid to/from the pistons and adjusts the rate of stroke out of thecylinder apparatuses 333, 334. An hydraulic cylinder apparatus 350 hasan extendable piston 351 pivotably connected to a pivot plate 353 at apivot point 365. The plate 353 is pivotably connected at a pivot point357 to the basket 306. A housing 350 of the apparatus 334 is secured toa mount 359 which is pivotably connected to the basket 306. A link 355is pivotably connected to the plate 353 at a pivot point 366 and thelink 355 is connected to a link 356 that is pivotably connected at apivot point 354 to a basket support 340. The basket support 340 issupported by the hydraulic cylinder apparatuses and by bases 341. Shafts367 of the basket supports 340 are pivotably mounted on the bases 341. Ascale 339 indicates the angle of the support 340 with respect tohorizontal (i.e. assuming the skid or base 302 is level). The support340 is connected to springs 346, 343 which support basket mounts 345 and342, respectively; and similar springs and mounts are on the other sideof the basket.

In another aspect the plate 365 is deleted and the hydraulic cylinderapparatuses are oriented almost vertically and the hydraulic cylinderapparatuses' pistons 351 are pivotally connected to the basket support340 for selectively raising and lowering it to adjust beach extent.

FIG. 10C shows the basket 306 tilted as compared to the basket 306 asshown in FIG. 10A.

In one aspect a vibratory separator or shale shaker according to thepresent invention may employ a material flow sensor which produces asignal indicative of the presence or absence of material flowing ontoscreen apparatus; e.g., but not limited to, drilling fluid with drilledsolids flowing onto screen apparatus of a shale shaker. Such anindication is valuable in insuring that, upon flow commencing againfollowing cessation of material flow which is common when drilling isstopped, a screen or a basket is not inclined at such an angle that arelatively low depth pool is formed resulting in the loss of untreateddrilling fluid flowing off a screen exit end. By adjusting screen orbasket angle so that flow recommencement is accommodated, a pool isformed of sufficient depth and extent that all or the great majority ofmaterial is treated and an optional amount of drilling fluid flowsthrough the screen and is recovered.

Optionally, a shaker 300 as shown in FIGS. 10A and 10B (with or withouta sensor or sensors like the sensor 320 a and/or 320 b) has a materialflow switch device 307 connected to vibratory separator adjacent amaterial input tank like the tank 308 for sensing when material isflowing. The device 307 may be any suitable known flow sensor apparatus,including, but not limited to paddle switch systems, including, but notlimited to, FS-550 Series paddle switches from Gems Sensors Co.

The device 307 is in communication with and controlled by the controller330 and, in one aspect, signals from the device 307 override signalsfrom sensors like the sensors 320 a and 320 b so that the controller 330knows that material flow has ceased (rather than an indication from thesensors 320 a, 320 b that the pool is very shallow). In response tosignals from the device 307 the controller 330 can activate theapparatus for adjusting basket angle.

Once material flow into the basket is again proceeding, the controller330 (acting upon signals from the sensor 320 a and/or the sensor 320 b)adjusts the basket angle to maintain the desired beach extent. Althoughone particular flow sensor has been mentioned, it is to be understoodthat any suitable known flow sensor device or system may be used,including, but not limited to, ultrasonic transducer systems.

The controller 330 may be any suitable known commercially availablecontroller apparatus, including, but not limited to computerizedsystems, digital signal processor systems, programmable logic controllersystems, and/or microprocessor systems. One suitable sensor apparatusand associated control system is the model XPS-10 and Hydro Ranger 200from Siemens.

FIG. 10F shows schematically a vibratory separator or shake shaker 400according to the present invention which has a screen-supporting basket402 with pivot members 414 pivotally mounted on supports 404 on a skidor base 406. Adjustment apparatuses 408, 410 on either side of thebasket 402 (like any adjustment apparatus described herein) raise andlower an end 412 of the basket 402, pivoting it about the pivot members414. In one aspect a rear line 416 of a beach area 420 of a screen 430supported in the basket 402 coincides with a line between the pivotmembers 414.

A sensor 418 (like any sensor disclosed herein, including but notlimited to those in FIGS. 1-10A) is positioned above a fluid entry endof the screen 430 on a connecting member 422 connected to the basket402. A sensor 451 (like any sensor herein) is positioned above a fluidentry end of the screen 434 and may be conveniently connected to a baror beam which is connected to the tank 450 and/or to the basket 402.Material flows from a screen 432 to the screen 430 and from a screen 434to the screen 432. Any suitable tank 452 and/or fluid introductionapparatus may be used. Vibrating apparatus 440 vibrates the basket 402.

A power apparatus 441 connected to the shaker 400 powers the adjustmentapparatuses 408, 410 and may be located at any suitable location on theshaker 400 including, but not limited to, on the basket 402 or on theskid 406. Optionally the power apparatus 441 is any such apparatus orsystem disclosed herein. In one aspect the power apparatus 441 includesan hydraulic pump in fluid communication with an hydraulic fluidreservoir 440 via a line 444 and the apparatuses 408, 410 arehydraulically-powered apparatus in fluid communication with the pump vialines 442, 443. Control apparatus 450 (as any disclosed herein) controlsthe apparatus 441, the sensor 418, a sensor 460, a controller 456,and/or the sensor 451. Optionally, a material flow sensor 460 connectedto the tank 452 (or at any suitable location in the separator 400) whichis like the sensor 307, FIG. 10A, senses the presence or absence ofmaterial flowing from the tank 452 onto the screen 434. The sensor 460is in communication with the control apparatus 450 and, in response tosignals from the sensor 460, the control apparatus 450 adjusts thebasket angle to accommodate material flow and to adjust forrecommencement of flow following flow cessation. Optionally, a flow ratecontroller 456 controls the amount of fluid introduced onto the screen434 from the weir tank 452 and a control switch 455 of the controller456 is in communication with the control apparatus 450.

It is within the scope of this invention for the apparatuses 408, 410 tobe located at any desirable effective location with respect to thebasket, as may be the case with any adjustment apparatus disclosedherein.

The present invention, therefore, in some and not necessarily allembodiments, provides a vibratory separator having a screen support orbasket for supporting screen apparatus for treating material introducedinto the vibratory separator, the basket on a base and pivotable withrespect thereto, vibratory apparatus connected to the basket forvibrating the basket, screen apparatus supported by the basket, thematerial forming a pool on the screen apparatus, and a beach on thescreen apparatus adjacent the pool, measurement sensor apparatusconnected to the vibratory separator and positioned above the screenapparatus for measuring a distance from the measurement sensor apparatusto a top surface of the pool, the measurement sensor apparatus includinga signal production portion for producing signals indicative of saiddistance and for transmitting said signals, a control system forcontrolling and in communication with the measurement sensor apparatusfor receiving signals from the measurement sensor apparatus indicativeof said distance and for processing said signals to calculate a pooldepth corresponding to said distance, and angle adjustment apparatusconnected to the basket and controlled by the control system foradjusting angle of the basket, thereby adjusting extent of the beach.Such a vibratory separator may have one or some, in any possiblecombination, of the following: wherein the vibratory separator is ashale shaker and the material is drilling fluid with drilled cuttingstherein; wherein the screen apparatus includes at least an exit screenwith an exit end from which material separated by the screen apparatusflows off the screen apparatus for discharge from the vibratoryseparator, wherein the basket is at an angle such that the beach isformed adjacent an edge of the pool adjacent said exit end, and whereinthe control system controls extent of the beach; wherein the controlsystem controls extent of the beach to maintain the beach on the exitscreen; wherein the screen apparatus is a plurality of screens placedadjacent each other in the basket, each screen with an associated screensupport connected to the basket; wherein the angle adjustment apparatusincludes a basket support pivotably mounted to the base and movingapparatus for selectively moving the basket up and down; wherein thebasket has a fluid entry end and a fluid exit end and wherein the basketis pivotably mounted adjacent the fluid exit end, and wherein the angleadjustment apparatus moves the basket's fluid entry end; wherein themoving apparatus includes hydraulic cylinder apparatus for moving thebasket; wherein the hydraulic cylinder apparatus includes twohydraulically powered piston apparatuses, each on a side of the basketfor moving the basket; wherein each hydraulically powered pistonapparatus is pivotably interconnected with corresponding linkageapparatus, the linkage apparatus pivotably connected to the basketsupport adjacent the fluid entry end of the basket; wherein themeasurement sensor apparatus is ultrasonic apparatus; wherein theultrasonic apparatus is at least one ultrasonic apparatus; wherein themeasurement sensor apparatus is a plurality of distance sensorapparatuses; wherein the plurality of sensor apparatuses includes afirst ultrasonic sensor apparatus spaced-apart from a second ultrasonicsensor apparatus, the first ultrasonic sensor apparatus above one sideof the screen apparatus and the second ultrasonic sensor apparatus abovean opposite side of the screen apparatus; wherein the measurement sensorapparatus is from the group consisting of electrical, optical,electromagnetic, ultrasonic, acoustic, and pulse-echo apparatus; whereina rear boundary of the beach is along a rear beach line and the basketis pivotably connected to the base beneath the rear beach line; and/orwherein the angle adjustment apparatus is powered by power apparatus.

FIGS. 11A-11D show a shale shaker 500 according to the present inventionwhich is like a King Cobra Shale Shaker commercially available fromVarco International, Inc., but which has improvements according to thepresent invention. The shale shaker 500 has a skid or base 502 on whichis a basket 506 which is vibrated by vibration apparatus 504. From atank 508 fluid, e.g. drilling fluid with drilled cuttings and debristherein, flows onto a first screen 510 which is supported by a screensupport 510 a connected to the basket 506. Part of the fluid then flowsonto a second screen 511 supported by a screen support 511 a connectedto the basket 506 and then part of the fluid flows onto a last screen512 supported by a screen support 512 a connected to the basket 506.Part of the fluid flows off an exit end 512 b of the screen 512 onto anoptional lower screen 513 which is supported by a screen support 513 aconnected to the basket 506. Fluid flows into a lower sump or receptacle503.

The fluid forms a pool 515 above the screens 510-512. A beach 516 is atthe exit end 512 b of the screen 512. It is desirable to control and/oroptimize the extent of this beach 516 and, in certain aspects, it ispreferred that the beach, as viewed in FIG. 11B, be sufficiently largethat no fluid flows untreated off the last screen 512.

An ultrasonic transducer sensor measurement apparatus 520 is connectedto the shale shaker, e.g. to a skid, base, tank or as shown to thebasket 506 and is, optionally, positioned above the pool 515, e.g. overan entry end 510 b of the screen 510. The apparatus 520 is incommunication with a control apparatus 530 (e.g., but not limited to, acomputer). The sensor apparatus generates a signal indicative ofsensor-to-pool distance which indicates depth of the pool 515 beneaththe sensor apparatus(es).

The control apparatus 530 selectively controls a bladder apparatus 536which selectively raises and lowers a rocker arm assembly 540 which, inturn, raises and lowers the basket 506 to which the rocker arm assembly540 is connected. Optionally the rocker arm assembly's angle withrespect to the horizontal is selectively adjustable by a mechanicalmechanism, e.g. any suitable known mechanical mechanism for moving therocker arm assembly up and down, e.g., but not limited to, a screwmechanism or an hydraulic or pneumatic piston device.

A top part 536 a of the bladder apparatus 536 contacts a lower surface541 a of a plate 541 of the rocker arm assembly 540. The bladderapparatus 536 inflates to raise the rocker arm assembly 540 and deflatesto lower it. A gas, e.g. air, or a liquid, e.g. a water-glycol mixture,can be used to inflate the bladder apparatus 536. The control apparatus530 controls the bladder apparatus 536. It is within the scope of thepresent invention to use, instead of the air bladder apparatus 536, tomove the rocker arm assembly up and down: a linear actuator device orother electronically-operated device; a hydraulically-powered device,e.g. an hydraulic cylinder system; or an air-over-hydraulic apparatus,e.g. a system with a liquid-filled tank with air pressure. In oneparticular embodiment the air bladder apparatus 536 is a commerciallyavailable Model 20-2 from Firestone Company. Although only one airbladder apparatus 536 is shown, it is within the scope of the presentinvention to use two such apparatuses, one on each side of the basket506.

The rocker arm assembly 540 has pivot shafts 542 which pivot incorresponding recesses 543 of mounts 544 on the skid 502. The rocker armassembly 540 has two side members 545 interconnected with an end member546. Spring mounts 54, welded to the basket 506, support springs 548which are connected to the brackets 549.

An optional ultrasonic sensor apparatus 522, in communication with thecontrol apparatus 530, senses whether or not there is fluid flow fromthe tank 508 to the pool 515. If a “no-flow” signal is generated by theapparatus 522 and sent to the control apparatus 530, then the basket istilted to its maximum uphill angle in anticipation of a next rush ofmud. An optional ultrasonic sensor apparatus 524 senses the location(height) of the plate 541, and produces a signal indicative of thislocation, which is a signal whose value corresponds to the angle of therocker arm assembly 540 and, therefore, to the angle of the basket 506(and which correlates with signal values from the apparatus 522). In oneaspect, the control apparatus 530 computes the basket angle based on thesignal from the ultrasonic sensor apparatus 524 and correlates thiscomputed angle with the value for the pool depth based on the signalfrom the ultrasonic sensor apparatus 520. If these two values correlate,this indicates the system is working properly. If there is a discrepancybetween the values (from the ultrasonic sensors) (e.g. a discrepancycaused by high flow, downhill basket orientation or low fluid level)this indicates a measurement problem and the control apparatus 530 thenadjusts the basket to a fully uphill angle until there is no suchdiscrepancy.

Optionally, the shale shaker 500 includes a variable frequency drive 550(optionally in an enclosure rated for a Class 1, Division 1, or Zone 1hazardous area) whose functions include varying the rpm's of thevibration apparatus 504 and thus varying the G-forces (acceleration)imparted to the basket 506 by the vibration apparatus 504; and changingthe direction of rotation of the vibration apparatus 504 therebychanging the motion of the basket 506, e.g. from linear motion toelliptical motion. In one particular aspect the vibration apparatus 504includes a Model VMX 18-8300-80 vibrator or a Model VMX 18-8300-110 fromMartin Engineering which have dual motion motors with the capability ofchanging an imbalance of weights based on rotation direction to changemotion, e.g. from linear to elliptical (or vice versa). The controlapparatus 530, and/or the ultrasonic sensor apparatus 524 and/or theapparatus 550 may be located at any convenient location on the shaleshaker 500. As shown in FIG. 11A they are protected within an enclosure554 formed of parts of the tank made of resilient material, e.g. metalor composite. Alternatively the drive 550 is located in a separateenclosure 554 a (shown by dotted lines).

Apparatus 552 provides a channel 553 for fluid in the tank 508 to bypassthe screens 510-512 and flow directly into the receptacle 503.

FIG. 13 shows a computer 560 which can be used, in one aspect, for thecontrol apparatus 530. Optionally, the computer 560 is positioned withinan enclosure 561 which is suitable for installation in a Class 1,Division 1 or Zone 1, hazardous area. AC Power is input to an AC to DCtransformer 562 which provides power to a power supply 579 and to apower supply 563 (which in turn supplies power to barrier devices 564,565, and 566). The power supply 563 provides power, e.g. 24 VDC, to apower supply 567 of an Input/Output device 568. The power supply 579provides power (e.g. 5 VDC) to a single board computer 569 which runs acontrol program and reads the I/O device, and sends control signals toelectrically actuated valves (e.g. 670, 671, FIG. 14) to control theshaker's basket angle. The power barrier devices 564-566 provide power,e.g. 24 VDC, to various intrinsically safe (“IS”) devices, e.g. theultrasonic sensor apparatuses. The computer 569 can be programmed toprovide a basket angle reset to reset a value of the ultrasonic sensorapparatuses' measurement of a “home” position of the basket (e.g. amaximum uphill angle).

Analog barrier devices 571 and 572 limit the power of signals on analogdevices, i.e. the ultrasonic sensors. Supply 567 provides power to thedevices 573-576. A digital input card 573 receives digital input signalsfrom other devices, e.g. the VFD and user push buttons. A digital outputcard 574 outputs digital signals to other devices, e.g. to the VFD. Arelay card 575 provides switch openings and closures for sending controlsignals from the computer to other devices, e.g. control valves. Ananalog input card 576 receives analog signals from other devices; e.g.from the ultrasonic sensor apparatuses.

Optionally the Input/Output device 568 may have a switch or connection578 for communication with a system (e.g. a computer or computer system)apart from and/or remote from a shale shaker or vibratory separator,e.g., but not limited to an Ethernet Input/Output Controller which, inturn, provides to connection to other systems, e.g. the Internet.

FIG. 14 illustrates schematically a system 600 according to the presentinvention which is like the systems shown in FIGS. 11A-13. A shaker 601(e.g. like the shaker 500 or any shaker disclosed or referred to herein)has a rocker arm assembly 640 (e.g. like the assembly 540) which can beraised and lowered by a bladder apparatus 636 (e.g. like the apparatus536) which is mounted on a skid 602. Vibratory motors 604 (e.g. like themotors 504) vibrate a basket 606 (e.g. like the basket 506).

Ultrasonic sensor apparatuses 620, 622, 624 (e.g. like the apparatuses520, 522 524) provide signals to a control system 630 (e.g. like thecontrol apparatus 530) for sensing system parameters and for controllingthe rocker arm assembly to adjust basket angle and to control the motors604. The control apparatus 630 is housed within an enclosure 654 (e.g.like the enclosure 554).

An optional variable frequency drive system (“VFD”) 650 (e.g. like thesystem 550) in an enclosure 654 a (e.g. like the enclosure 554 a) is incommunication with the system 630 and provides control of the motors 604(i.e. control of G forces on the screens and/or control of type ofmotion) and control of the basket angle. In one particular aspect thesystem 630 has manually-operable push buttons 631-634. The buttons631-633 provide for calibration of the ultrasonic sensor apparatuses620, 622, 624, respectively. The button 634 is a system re-set button.In one aspect the buttons are tied to a digital input card in theenclosure.

The VFD 650 has manually-operable push buttons 651-656 and 658-659 whichfunction as follows:

-   -   651 On    -   652 Off    -   653 Switch between linear/elliptical motor motion    -   654 Power to system 630    -   655 Switch between automatic and manual mode    -   656 System 650 re-set    -   658 Move basket up (increase basket angle)    -   659 Move basket down (decrease basket angle)

Valves 670 and 671 are electronically-operated valves. Power is providedto the valve 670 via a power line 681 from the system 630 and to thevalve 671 via a power line 684. The basket is raised or lowered byselectively opening or closing the valve 670 which permits fluid 692(e.g. a water-glycol mixture) to flow to or from the bladder apparatus636 from a controlled pressure reservoir 691 in a line 675 and to orfrom the valve 670 in a line 677.

The valve 671 controls air flow between an air inlet 672 and thereservoir 691. Air under pressure from a source 692 flows in a line 693to the air inlet 672 and then via the lines 678 and 674 to and from thereservoir 691 to move the fluid 692 for raising and lowering of thebasket to adjust basket angle.

A cooler 673, e.g. a vortex cooler apparatus in fluid communication withthe air inlet 672 via lines 678 and 685, cools the interior of theenclosure 654 a.

FIGS. 15-17 show a shale shaker 70 according to the present inventionwhich has a screen-mounting basket 72 and a bridge 74 on which aremounted two vibrating apparatuses 75. The basket 72 has brackets 76 towhich are secured helical springs 77. Each spring 77 is secured to abase member 77 a. As shown in FIG. 17, an optional housing 79 may beused on sides of and beneath the shale shaker 70. Optionally (and as maybe the case with any shale shaker disclosed herein according to thepresent invention or with any known prior art shaker or vibratoryseparator) an electronic tracking apparatus 71 is on the housing 79, butmay, according to the present invention, be within any suitable memberor part of a shale shaker; and, optionally, such a tracking apparatushas a container or housing made of composite material and/or is encasedwithin or coated with composite material. Any known tracking device,apparatus, or system may be used, including, but not limited to knownsatellite tracking systems.

The present invention, therefore, provides, in at least certainembodiments, a vibratory separator or shale shaker with a base; a basketmovably mounted on the base and for supporting screen apparatus fortreating material introduced into the vibratory separator, the basket onthe base and pivotable with respect thereto; vibratory apparatusconnected to the basket for vibrating the basket; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; angle adjustment apparatus connected to the basket foradjusting angle of the basket; sensor apparatus, e.g., ultrasonic, forsensing a parameter indicative of basket angle and for providing asignal corresponding to said basket angle; control apparatus forreceiving signals from the sensor apparatus and for controlling basketangle based on said signals; the angle adjustment apparatus including arocker arm assembly with a first end and a second end, the first endpivotably mounted to the base adjacent and beneath a material input areaof the vibratory separator and the second end adjacent and beneath amaterial exit end of the vibratory separator; and the angle adjustmentapparatus including movement apparatus with a part thereof in contactwith the second end of the rocker arm assembly for moving the second endup and down to change basket angle, the movement apparatus controlled bythe control apparatus. Such an apparatus may have one or some, in anypossible combination, of the following: wherein the vibratory separatoris a shale shaker and the material is drilling fluid with drilledcuttings therein; wherein the vibratory apparatus comprises two motorsfor vibrating the basket, the two motors providing dual motioncapability; wherein the screen apparatus includes at least an exitscreen with an exit end from which material separated by the screenapparatus flows off the screen apparatus for discharge from thevibratory separator, wherein the basket is at an angle such that a beachis formed adjacent an edge of a pool of material adjacent said exit end,and wherein the control system controls extent of a beach; wherein thesensor apparatus is ultrasonic sensor apparatus; wherein the ultrasonicsensor apparatus is at least one ultrasonic sensor apparatus; whereinthe sensor apparatus is a plurality of sensor apparatuses; wherein saidplurality of sensor apparatuses includes a first ultrasonic sensorapparatus spaced-apart from a second ultrasonic sensor apparatus, thefirst ultrasonic sensor apparatus for sensing material level in thebasket and the second ultrasonic sensor apparatus for sensing rate ofmaterial flow into the basket; wherein the measurement sensor apparatusis from the group consisting of electrical, optical, electromagnetic,ultrasonic, acoustic, and pulse-echo apparatus; flow sensor apparatusconnected to the vibratory separator for sensing the flow of materialonto the screen apparatus, the flow sensor apparatus controlled by andin communication with the control apparatus, and the control apparatusfor adjusting basket angle in response to signals from the flow sensorapparatus; wherein said plurality includes a third ultrasonic sensorapparatus for sensing basket angle; wherein the angle adjustmentapparatus is powered by power apparatus from the group consisting ofpneumatic power apparatuses, hydraulic power apparatuses and electricpower apparatuses; and/or wherein the movement apparatus of the angleadjustment apparatus includes inflatable bladder apparatus which isselectively inflatable to raise and lower the rocker arm assembly.

The present invention, therefore, provides, in at least certainembodiments, a vibratory separator or shale shaker with a base; a basketmovably mounted on the base and for supporting screen apparatus fortreating material introduced into the vibratory separator, the basket onthe base and pivotable with respect thereto; vibratory apparatusconnected to the basket for vibrating the basket; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; angle adjustment apparatus connected to the basket foradjusting angle of the basket; sensor apparatus connected to the basketfor sensing a parameter indicative of basket angle and for providing asignal corresponding to said basket angle; control apparatus forreceiving signals from the sensor apparatus and for controlling basketangle based on said signals; the angle adjustment apparatus including arocker arm assembly with a first end and a second end, the first endpivotably mounted to the base adjacent and beneath a material input areaof the vibratory separator and the second adjacent and beneath amaterial exit end of the vibratory separator; the angle adjustmentapparatus including movement apparatus with a part thereof in contactwith the second end of the rocker arm assembly for moving the second endup and down to change basket angle, the movement apparatus controlled bythe control apparatus; wherein the vibratory separator in one aspect isa shale shaker and the material is drilling fluid with drilled cuttingstherein; wherein the vibratory apparatus has two motors for vibratingthe basket, the two motors providing a dual motion capability; whereinthe screen apparatus includes at least an exit screen with an exit endfrom which material separated by the screen apparatus flows off thescreen apparatus for discharge from the vibratory separator; wherein thebasket is at an angle such that a beach is formed adjacent an edge of apool of material adjacent said exit end; wherein the control systemcontrols extent of a beach; wherein the sensor apparatus is ultrasonicsensor apparatus; wherein the sensor apparatus is a plurality of sensorapparatuses which includes a first ultrasonic sensor apparatus, secondultrasonic sensor apparatus, and third ultrasonic sensor apparatus forsensing basket angle, the first ultrasonic sensor apparatus for sensingmaterial level in the basket and the second ultrasonic sensor apparatusfor sensing material flow rate into the basket; the control apparatusfor adjusting basket angle in response to signals from the sensorapparatuses; and correlation apparatus for correlating signals from thethree ultrasonic sensor apparatuses to check system adjustment.

The present invention, therefore, provides, in at least certainembodiments, a vibratory separator with a base; a basket movably mountedon the base and for supporting screen apparatus for treating materialintroduced at a first end of the basket into the vibratory separator,the basket on the base and the first end pivotable with respect thereto,the basket having a second end spaced apart from the first end, materialexiting the basket at the second end; vibratory apparatus connected tothe basket for vibrating the basket; screen apparatus supported by thebasket, the material flowing onto the screen apparatus for treatment;angle adjustment apparatus connected to the basket for adjusting angleof the basket by pivoting the basket's first end; sensor apparatus forsensing a parameter indicative of basket angle and for providing asignal corresponding to said basket angle; control apparatus forreceiving signals from the sensor apparatus and for controlling basketangle based on said signals; and the angle adjustment apparatusincluding movement apparatus for moving the second end up and down tochange basket angle, the movement apparatus controlled by the controlapparatus.

Such an apparatus may have one or some, in any possible combination, ofthe following: wherein the vibratory separator is a shale shaker and thematerial to be treated is drilling fluid with drilled cuttings therein;wherein said plurality of sensor apparatuses includes a first ultrasonicsensor apparatus spaced-apart from a second ultrasonic sensor apparatus,the first ultrasonic sensor apparatus for sensing material level in thebasket and the second ultrasonic sensor apparatus for sensing rate ofmaterial flow into the basket and wherein said plurality of sensorapparatuses includes a third ultrasonic sensor apparatus for sensingbasket angle, and correlation apparatus for correlating signals from allthree ultrasonic sensor apparatuses to check system adjustment; avariable frequency drive connected to the basket for controlling thevibratory apparatus; computer apparatus for controlling the vibratoryseparator; wherein the computer apparatus performs the functions of avariable frequency drive; and/or boost push button apparatus formanually changing forces applied by the vibratory apparatus.

The present invention, therefore, provides, in at least certainembodiments, a method for treating material introduced to a vibratoryseparator, the method including introducing material to a vibratoryseparator, the vibratory separator like any according to the presentinvention, treating the material in the vibratory separator, andadjusting the angle of the basket with angle adjustment apparatus. Suchan apparatus may have one or some, in any possible combination, of thefollowing: wherein the vibratory separator is a shale shaker and thematerial is drilling fluid with drilled cuttings therein; and whereinthe vibratory apparatus comprises two motors for vibrating the basket,the two motors providing dual motion capability, the method furtherincluding changing motion using the two motors.

The present invention, therefore, provides, in at least certainembodiments, beach adjustment apparatus for adjusting extent of a beachon a screen of a vibratory separator, the screen mounted to a vibratablebasket of the vibratory separator, the beach adjustment apparatusincluding an end-pivotable basket support for supporting the basket, theend-pivotable basket support pivotable at a pivot end thereof, the endpivotable basket support having a second end spaced-apart from the pivotend, the second end positionable near an exit end of a vibratoryseparator; apparatus for pivoting the end-pivotable basket support atits pivot end; and the apparatus for pivoting the end-pivotable basketsupport including movement apparatus having a part thereof forcontacting the second end of the end-pivotable basket support forfacilitating pivoting movement of the end-pivotable basket support toraise and lower the second end to adjust the extent of the beach.

In certain aspects an automatic boost minimizes fluid loss over the endof a shaker during a flooding situation. Several standard prior artshakers operate with a fixed shaking force and frequency, and a manuallyadjustable basket angle and vibrate with a nominal acceleration(g-force) that is measured without drilling fluid. The addition ofdrilling fluid adds mass to the system, which decreases the systemacceleration. In addition, the angle of the basket is often manuallyadjusted according to the fluid level. Adjusting the basket angle keepsthe fluid extent (beach) at a desired point, e.g. in triple screenshakers at about the end of a third screen. However, when fluid flowrates change frequently in the field, the basket angle is often notadjusted to its optimum position. If the basket angle is left in thefully uphill position, several screens may be running dry, which candecrease screen life. If the basket angle is left in a downhill positionfor correct beach length, whole mud can be lost over the end of theshaker when flow rates increase.

In certain embodiments, a shaker according to the present inventionautomatically adjusts the basket angle according to the fluid level.Thus, the basket is tilted downhill when there is little flow cominginto the shaker. When the flow increases, the basket is automaticallytilted uphill to keep the beach at approximately the same position. Ifthe basket has been tilted fully uphill, and the fluid level ismeasuring high for a certain period of time (programmable into theshaker computer and/or controller), then the computer automaticallysignals the VFD (variable frequency drive, or inverter) to drive themotors faster, referred to as an “automatic boost” feature. Increasingthe motor speed increases the force applied to the basket and fluidsystem. This in turn increases the basket acceleration, which increasesthe flow capacity of the shaker. Thus, this automatic boost featurehelps prevent a shaker from flooding and losing whole mud.

Many traditional prior art shakers operate with a fixed motion profile.These motion profiles are either linear, elliptical, or circular. Eachmotion tends to be best suited for a particular mud condition. Forinstance, circular motion can perform well with sticky clays, linearmotion performs well in high flow conditions, and elliptical motion canoffer a compromise between linear and circular. Some current prior artshakers can manually switch motion profiles between linear andelliptical. These shakers include the Brandt King Cobra+, Brandt KingCobra II, and Swaco Mongoose. Certain shakers according to the presentinvention may have a custom shaker motion profile which is ellipticalwith varying aspect ratio. A motion profile is the motion shape atdifferent points on the shaker, a motion imparted to material moving onthe shaker. For example, overall shaker performance can, in certainaspects, be improved by having a different motion shape at the dischargeend of a shaker than at the feed end or in the middle of a shaker. Inone aspect, the tuned motion in the feed end of the shaker is a thinellipse (approximately 5% aspect ratio), which can appear to be linear;the tuned motion near the center of the basket is a medium shapedellipse (approximately 15% aspect ratio); and the tuned motion near thedischarge end of the shaker is a fatter ellipse (approximately 30%aspect ratio). The acceleration level and angle of attack remainreasonably consistent and uniform front to back. In one aspect, thismotion profile enhances performance in drilling mud with sticky clays.With this configuration, the conductance is increased (fasterelimination of liquid from the mud) with the thin ellipse at the feedend of the shaker. The conveyance is enhanced at the discharge end ofthe shaker by the more pronounced elliptical motion. The more linearmotion at the feed end of the shaker processes a higher maximum fluidflow rate, while the more elliptical motion at the discharge end of theshaker conveys sticky clays better. Elliptical motion is effected byusing different weights on vibratory motors creating a forcedifferential which results in motion perpendicular to the line of forceon the basket and a torque imbalance which makes the basket rotate aboutthe center of mass producing elliptical motion; and/or such motion isproduced by varying motor position with respect to the center of mass.In a shaker according to the present invention an operator can manuallyswitch the shaker motion profile between linear, elliptical, andcircular motion (with appropriate motor location and/or spacing and/orwith a motor at the basket center of mass). In another aspect, a shakeraccording to the present invention has the ability to produce all threestandard motions (linear, elliptical, and circular), and a custom motion(change shape front to back on the basket), then the best motion profilecan be chosen based on the mud state and shaker state. For instance, ifthe mud flow rate is very high, linear might be the best motion profile.If very sticky clays are encountered, then circular motion might bepreferred. If the mud does not have a large amount of sticky clays, andthe flow rate is not extremely high, then elliptical motion might bebest. Other conditions may point towards one motion as being the best ata certain time. For instance, an intelligent shaker according to thepresent invention can choose the appropriate motion, and turn motors onand off, or run the motors forward or reverse to achieve the bestmotion. Motors can have brakes applied to stop the rotation of the motorweights in order to achieve the desired motion.

Currently, many prior art shakers run at a fixed or at leastinfrequently changing state. The shaker state can be described by suchparameters as screen mesh, acceleration amplitude, motion profile,basket angle, angle of attack, and vibration frequency. In addition,many typical shakers operate without knowledge of the state of thedrilling mud. Some of the parameters that contribute to the mud stateinclude viscosity, temperature, flow rate, fluid level in the shaker,specific gravity, solids content, and stickiness of the solids.Typically, many prior art shakers are designed to operate at a nominalshaker state that works reasonably well over a range of mud states.Experienced operators change the shaker state periodically to increaseperformance for the current mud state. Prior art mud sensors sense suchparameters. Inexperienced operators may operate the shaker at asub-optimal state for the conditions of the mud. Even experiencedoperators may not have the time to change the state of the shaker tomatch changing mud conditions. A shaker supplied with information aboutits own state and the state of the drilling mud can operate closer tooptimum for given conditions. Certain shakers according to the presentinvention measure their own performance to assist in optimizingoperation.

In order to operate intelligently, a shaker according to the presentinvention has a computer or other programmable apparatus of some form toread state information, make decisions to optimize performance, andimplement the decisions (e.g., but not limited to, a controller 330,FIG. 10E; control apparatus 550, FIG. 11A, computer 560, FIG. 13; orcontrol apparatus 630, FIG. 14). The computer, in one aspect, isconnected to an I/O (input/output) device or devices that read valuesfrom various sensors and send outputs to actuators, motor drivers,and/or other equipment. Sensors (e.g. sensors within a shaker,container, tank and/or in a flow line or conduit; e.g. sensors MS, FIGS.2A and 9) indicate and measure some or all of the mud state parameters.

With information about the mud state, the current shaker state, and/orother performance measurements, an intelligent shaker according to thepresent invention controls its own state to enhance and/or to optimizeperformance. Shaker states that can be controlled (with user selectablecontrols and/or automatically based on sensor readings) include basketangle, acceleration magnitude, motion profile (linear, elliptical, orcircular; e.g. detect non-sticky free-flowing material and use linearmotion; e.g. detect sticky clays, change to elliptical motion or detectflow is low for a long time and change to elliptical motion), vibrationfrequency, angle of attack (angle of basket motion relative to itshorizontal position; e.g. change center of mass of basket and/or motorlocation).

In certain aspects, the automatic boost feature is a specific instanceof controlled acceleration. In this case, the shaker acceleration istemporarily increased to a pre-determined value, e.g. in order toaccommodate unusually high mud flow. More generally, when the shakeracceleration is controlled, then it can be varied over a continuousrange (e.g. for such control a monitoring device monitors anaccelerometer on or connected to a shaker basket and the monitoringdevice, e.g. a computer, PLC, or PID controller, sends a signal to aVFD). For instance, the acceleration can be controlled to be constantunder varying mud flow/loading. This is accomplished by measuring thebasket acceleration with an accelerometer located on the basket, in oneaspect near the center of mass, e.g. accelerometer AC in FIG. 1C;feeding back the signal from the accelerometer to a shaker computer (orPID controller, or to a remote computer); comparing the actualacceleration with the desired value; and changing the motor frequency orother driving force until the actual acceleration matches the desiredacceleration.

If a desired acceleration value is changed according to the states ofthe shaker and mud, then performance is further enhanced and/oroptimized. For instance, the acceleration level is adjusted to minimizeenergy consumption, or to use the minimum necessary acceleration basedon the fluid level in the shaker. This is useful since high accelerationcan lead to decreased screen life and solids degradation. If the fluidlevel in the basket increases above the desired level, then the basketangle is decreased to tilt the basket uphill. This can only be done to acertain point. Once the basket is fully uphill, the acceleration isincreased, which processes more fluid and lowers the fluid level in theshaker basket.

For condition-based maintenance, the shaker machine state and/or shakerhistory are used to predict when to perform maintenance on the machine.The maintenance schedule of a standard shaker often requires addinggrease to the vibrator motor bearings after a period of time. Dependingon how much the shaker was actually operating over this time causes theactual maintenance time frame to differ from the static, documentedschedule. Proper greasing is especially important to motor bearings(e.g. bearing apparatus BA shown in dotted lines in FIG. 11C). Toolittle grease can cause increased friction, increased temperature, andpremature bearing failure. Too much grease can cause increased pressurein the bearings, increased temperature, and premature bearing failure.Further, the ambient temperature that the motor operates in will affectthe maintenance schedule. Other factors include motor force.

One factor that can be used to predict when bearing grease needs to beadded is the operating temperature of the bearing. According to thepresent invention the bearing operating temperature is sensed with asensor (e.g. sensors in the motor adjacent the bearings, e.g. sensor SR,FIG. 11C) and is then sent to a computer that compares it to the ambienttemperature and the desired temperature level for greasing, then theoperator can be notified (e.g. by any controller as described herein)when it is time to grease the motor bearings. Also, a computer (on theshaker, on site, or remote) or other device is used to keep track of themotor's operational time. When the operational time reaches the desiredmaintenance time, the operator is notified of the required maintenance.This operational time can be adjusted according to the ambienttemperature and current bearing temperature.

Certain shakers according to the present invention have interfaces andcommunications with on-site and remote controllers, computers, systems,networks, and/or the Internet. An automatic shaker according to thepresent invention has a web (e.g. Internet) interface between on-sitepersonnel at the shakers location and personnel and/or computerizedinformation remote therefrom for maintenance and/or re-programmingoperations. This enables technicians during setup, maintenance, ortroubleshooting to monitor the status of the shaker, including allprogram parameters, and adjust the program parameters on the fly, whilethe shaker is shaking and the software is running. Additionally, thetechnicians can load software updates to the shaker. The softwareupdates can be accomplished either through the web interface, or byphysically changing a programmable media, e.g. a removable Compact Flashcard. Such a shaker can have a local Ethernet network in its computerenclosure on the shaker. With a wireless radio attached to the shakercomputer network, the shaker computer can communicate wirelessly throughthe closed explosion-proof enclosure with the Internet and/or to alaptop (see, e.g. laptop LAP shown schematically in FIG. 26) with awireless network connection. In one aspect, this works up to about 20feet from the shaker while the shaker is running. The range can beextended with the use of a window in the computer enclosure, or with theuse of an antenna in an explosion-proof enclosure with a glass dome.Additionally, the technician can connect to the computer network with anetwork cable.

In certain aspects, a shaker according to the present inventionwirelessly connects to the Internet through a drilling rig's networkconnection. This enables remote monitoring, troubleshooting, andcontrol. For instance, if a rig has a problem, technical support iscontacted and is able to view the shaker state, view program variables,change settings, and update the software remotely, from anywhere in theworld with an Internet connection.

The software in the shaker computer, in certain aspects, has the abilityto be upgraded to communicate with other Drilling Equipment (DE)machines such as tele-operated drilling chairs, Drawworks, rackers, mudcontrol equipment, and top drives. Optionally, local and/or remote userinterfaces with touchscreens are provided. These allow an operator toview more information about the state of the shaker, including alarms,warnings, health checks, and suggested changes to the shaker. Suggestedchanges to the shaker can include increasing or decreasing the screenmesh, greasing motor bearings, replacing sensors, or checking basketangle actuators.

In certain embodiments, (see, e.g. FIGS. 18-28) systems according to thepresent invention provide tests, checks, and intelligent diagnosticsspecific to oil rig operational scenarios, to vibratory separatoroperation and, in particular aspects, to shale shaker operationalscenarios which enhance oil rig safety and efficiency of oil fielddrilling operations, in certain particular aspects when applied to anautomatically operated shale shaker with an electronic and/orcomputerized control system to ensure continuous and proper systemavailability during downhole operations. In certain systems according tothe present invention failures, performance degradation and/or predictedfailures are reported to service personnel that perform additionaldiagnostics or dispatch field personnel to replace or repair the systemsas necessary.

The present invention provides a method and apparatus for remotelymonitoring, analyzing and affirmatively notifying appropriate personnelof problems and events associated with an oil recovery system comprisingone or more, e.g. hundreds, of oil rigs over a vast geographic area. Thepresent invention provides a monitoring and reporting system that isreferred to as a Health Check system. The present invention provides avariety of performance monitoring sensors at each oil rig in an oilrecovery system, and, in certain aspects, for each shale shaker of anoil rig. The results of selected diagnostics, which are run on each oilrig and/or on each shaker, are reported to a central server. The centralserver automatically populates a database for the oil recovery systemand displays a red/yellow/green/gray color-coded report for each rigand/or for an entire oil recovery system. The present invention alsoaffirmatively alerts appropriate personnel of actions required toaddress events associated with an oil rig in an oil recovery system. Thediagnostics performed at each oil rig are configurable at the individualrig. The central server need not change its reporting and displayprogram when changes are made to a heath check at an oil rig. Thepresent invention provides a dynamic oil rig status reporting protocolthat enables construction and display of a tree node structurerepresenting an entire oil recovery system status on a single screen.Preferably, top level information is presented on a single screen, anddetailed information presented when one drills down in to other screens.Thus, the present invention enables rapid visual affirmation of a systemHealth Check.

A Health Check is an automated test that is running on the rig andmonitoring something, e.g., but not limited to, a shale shaker orshakers, for acceptable performance, indication of problems, etc. Thesetests could be applied to equipments, drilling processes, or anoperator's usage of particular drilling equipment, e.g., but not limitedto, shaker(s). The results are then communicated to a central serverlocated in a service center through a unique protocol, which allowsautomatic distribution and display of information and/or directly from ashaker to an Internet interface. A test program on a rig can be modifiedand that change will flow automatically through communication, storageand display of the resulting Health Check data for the rig.

The service center based web server allows secure access to Health Checkresults. The results are presented in “top down tree” mode withred/yellow/green/gray colors. The red color indicates the failure of atest or flagging an event of interest, the yellow color indicates thatthe health test has found some abnormality that may need attention,green indicates successful completion of a test, and gray colorindicates inability to conduct a test. The bottom-most node of the “topdown tree” contains the results of a Health Check. The work-case resultis successively carried up to the next level, until topmost node (whichin most cases is the drilling rig, group of rigs or oil recovery system)is reached.

Each Health Check result can be configured to generate a message (email,phone call, PDA, etc.) to alert single or multiple persons in case oftest failure. The data transfer protocol is well defined, such thatother development groups or third parties can easily develop HealthCheck tests, generate results and feed information to the centralserver. Test results are transferred from the rig to the server using anovel data protocol that dynamically defines the structure of the data,that is, the node tree structure of the data by the naming convention ofthe protocol. Thus, the results are simply stored and displayed usingthe structural definition provided in the communication protocol. Thisallows for extreme flexibility in the definition of new programs andresults to run and report at oil rigs without requiring a change in thecommunication protocol, notification function or the display and storagefunctions at the central server. The bottom-most nodes in the treestructure contain test results. Each test comes into the central serveras a record containing node information as to where the information fitswithin the tree structure, an identifier for the test, a test result(red/yellow/green/gray) and intermediate data such as error codes,operator entry data and test data description. Thus, no resultsprocessing need occur at the central server. The central server onlyarchives and display results and issues affirmative (withacknowledgement) and regular notifications as required.

Events or conditions can be set for notification, thus, once the eventor condition occurs and after it is set for notification, a notificationis sent to a designated person reporting the event of condition. A listof persons can be associated with each oil rig and event or condition. Anotification can be sent to a cell phone, PDA or other electronicdevice. A notification can comprise a text, audio or video message to auser. A notification tells the rig status color code, text, aural orvideo. A user can call into the central server to check the status of anoil rig or oil recovery system. The status returned is a notificationmessage indicating that the rig is okay or that a problem or conditionof interest has occurred. Thus, the Health Checks are different thanalarms, although alarms (including those alarms generated by prior orlegacy systems) can be used as inputs to a Health Check where the alarmsare processed and considered by Health Check rather than sending analarm immediately to oil rig personnel. Health Check may indicate thatpiece of equipment is out of range and should be replaced in the nearfuture, however, supercritical alarms can be processed by Health Checksto generate an immediate notification.

In certain aspects, the present invention (and any and all steps and/orevents described above for any scenario) is implemented as a set ofinstructions on a computer readable medium, comprising ROM, RAM, CD ROM,Flash or any other computer readable medium, now known or unknown, thatwhen executed cause a computer or similar system to implement the methodand/or step(s) and/or events of systems and methods according to thepresent invention, either on-site or remotely or both.

The present invention is described herein by the following example foruse on drilling rigs, however, numerous other applications are intendedas appropriate for use in association with the present invention.

The present invention provides a user interface, which, in one aspect,is preferably mounted to existing rig floor structure and also providesa pedestal mount with adjustable height, for convenient choke operation.A wireless version is also provided.

The present invention supports real-time two-way data communication,e.g., with Varco International, Inc.'s RigSense and DAQ JVM, and withother commercially available information systems. In one aspect anysensors whose data is used by the present invention (for control and/ordisplay) are directly connected to the present invention, including, butnot limited to, sensors on a shale shaker or shakers.

In one aspect, when the RigSense system is present in an embodiment ofthe present invention, the RigSense system provides data archiving andexpanded data displays functionality to the present invention. Thepresent invention provides a user interface integrated into othersystems such as the RigSense system, DAQ JVM and VICIS; Real-Time WellControl, supervisory control specific to well control tasks; andAutomated well control, which may be entire process or selectedsub-tasks. One of the primary impacts perceived on existing products andservices in which integration and/or implementation of the presentinvention is performed is additional capability for taking control ofand/or being in control of the choking operation via a distinctintervention, so that control is clearly being exercised by users atother stations and by automated controllers.

A key factor for efficient utilization and integration of the presentinvention into the operator's working environment is the presentinvention's provision of manual controls for high-frequency user controlactions in lieu of touch screen control consoles. Additional automatedfunctionality is provided such as automatic pressure-set control for usein association with the touch screen and provides benefit in the controlarea, particularly in emergency stations. In an alternative embodiment atouch screen user interface is provided.

In another embodiment, the present invention is implemented as a set ofinstructions on a computer readable medium, comprising ROM, RAM, CD ROM,Flash or any other computer readable medium, now known or unknown thatwhen executed cause a computer to implement a method of the presentinvention.

The present invention provides a method and apparatus for remotelymonitoring, analyzing and affirmatively notifying appropriate personnelof problems and events of interest associated with an oil recoverysystem comprising one or more, e.g. hundreds, of oil rigs over a vastgeographical area or a single rig. The present invention provides amonitoring and reporting system that is referred to as a Health Checksystem. The present invention provides a variety of performance, processand equipment monitoring Health Checks and equipment sensors at each oilrig in an oil recovery system. The present invention provides a dynamicoil rig status reporting protocol that enables population and display ofa tree node structure representing an entire oil recovery system orsingle oil rig status on a single screen. Thus, the present inventionenables rapid visual or aural affirmation of a system Health Check.

Health Checks are not the same as alarms. An alarm is an immediatenotification to an operator that a known unacceptable condition has beendetected, requiring the operator's awareness of it and often some actionby the operator. A Health Check may use alarms in its logic, but it isby nature different than an alarm. A heath check is more general andmore diagnostic than an alarm, and does not require immediate action, atleast not on the oil rig. In the present invention, a problem isreported to a central server for reporting and diagnosis to servicepersonnel. A Health Check can apply to any equipment component orprocess, sensors, control systems, operator actions, or controlprocesses, etc.

The Health Check system comprises software containing test logic. Thelogic is configurable so that inputs, outputs and logic can be selectedby a user to test and look for any condition or event associated with anoil rig or oil recovery system. The overall system in certain aspectscomprises Health Checks running in real time on a computer at an oil rigand a communications network connecting the oil rig to a central serverto move data from the rig of a group of rigs to the server. The serverdisplays the results in hierarchical form. The server sends commands,application programs and data to the rig from the server.

The Health Check system of the present invention further comprises, incertain aspects, a central database populated with dynamic statusreported from oil rigs comprising an oil recovery system. The presentinvention further comprises a web page display for efficientlydisplaying Health Check results associated with a test, a rig, an areaor an oil recovery system. The web page results can be displayed on acomputer, cell phone, personal data assistant (PDA) or any otherelectronic display device capable of receiving and displaying orotherwise alerting (e.g., sound notification) a user of the status ofthe data. The preferred screen is a color screen to enablered/green/yellow/gray display results. Results can also be audio, videoor graphically encoded icons for severity reports, e.g., an audiomessage may state audibly, “situation green”, “situation red” or“situation yellow” or display a particular graphical icon, animation orvideo clip associated with the report to demonstrate a Health Checkseverity report. The present invention enables drilling down (that is,traversing a hierarchical data structure tree from a present node towardan associated child or leaf node), into a tree of nodes representingdiagnostic status, to a node or leaf level to access additionalinformation regarding a color-coded report.

The present invention also provides a notification system to immediatelyinform service personnel of problems as necessary, such as a message oremail to a cell phone or pager or computer pop up message. There is alsoa receipt affirmation function that confirms that a notification messagewas received and acknowledged. Secondary and tertiary notifications aresent when a primary recipient does not acknowledge an affirmativenotification within a configurable time limit. A severity reportassociated with a given problem is represented by a blinking color whenit is unacknowledged and remains a blinking color until the givenproblem is cleared and returns to green or clear status. Severityreports once acknowledged change from blinking to a solid color. Reportsthat have been acknowledged by one user may be transferred or reassignedto another user upon administrative permission by a system supervisor orby requesting permission to transfer a second user and receivingpermission from the second user. A system supervisor can also display alist of users and severity reports being handled by the user, that is, alist of acknowledged and in progress severity reports assigned to aparticular user to view and enable workload distribution to facilitatereassignments for balancing the work load.

A dispatch may assign a work order to a group of particular severityreports. Once the work order is completed the system checks to see ifthe nodes associated with the work order have been cleared. The workorder provides a secondary method for determining if nodes associatedwith a work order have been cleared after a work is complete. The systemadministrator software program can also automatically check the workorder against the node state for a system check.

The advantages provided to the customer of a preferred Health Checksystem are substantially less down time due to the present invention'sHealth Check's ability to find or anticipate problems earlier and fixingthe problems faster, ideally before the customer becomes aware that aproblem has occurred. The present invention reassures the customer thatthe Health Check system is always on the job and monitoring andreporting on the oil recovery system twenty-four hours a day, seven daysa week. A customer or system user can always call in and confirm thestatus of an entire oil recovery system or single rig with a single callto the central server or a rig and receive a situation report, that issituation red, yellow, green or gray for the oil recovery system orsingle rig, as requested. The present invention enables more efficientuse of operational service personnel. The present invention finds andreports problems, potential problems and trigger events of interest,which enables rapid response and recovery in case of actual and/orpotential equipment or operator malfunctions or the occurrence of aparticular event. The present invention also helps to find problems atan early stage when the problems are often easier to fix, beforecatastrophic failure, thus creating less impact on the customer's oilrecovery system or individual oil rig. Health Checks according to thepresent invention provide a method and apparatus for providing anapplication program that acts as an ever-vigilant set of eyes watchingan entire oil recovery system or single rig to ensure that everything isokay, that is, operational.

In certain embodiments, all results for each oil rig in an oil recoverysystem or individual oil rig or equipment, e.g., but not limited to, ashaker or shakers, are worst-case combined so that the worst-caseseverity report bubbles to the top of the reporting tree and is reportedas the status for an entire oil recovery system, oil rig(s), event ofinterest, process, or equipment being analyzed. As discussed above, redis a worst-case severity report, followed by yellow severity report andthen green is the least severe report. Gray indicates no data available.Thus, if one or more tests reporting a red status is received from anoil rig, the red status bubbles up past all yellow and green statusreports and the status for the rig and the entire oil recovery system inwhich the rig resides is shown as red. Once the red report is cleared,yellow reports, if any, bubble up and the status of the oil recoverysystem, rig or equipment being viewed is shown as yellow, if a yellowreport is in a node tree transmitted from any oil rig in an oil recoverysystem. The status for a single oil rig bubbles up the worst-case reportas well, however, localized to the single rig or rigs underinvestigation, unless grouped. When grouped the worst-case status forthe group is reported. For example, if three rigs were reporting thefollowing scenario is possible: Rig 1 reports red, rig 2 reports yellowand rig 3 reports green. The status for a group selected to include rigs1, 2 and 3 would be red. The status for a group selected to include rigs2 and 3 would be yellow. The status for a group selected to include rig3 only would be green. Subsections within a rig can also be selected fora color-coded status report. Preferably, the gray is not cleared.Usually, if the test were not conducted for any reason, the status wouldtake gray color.

The present invention enables testing at the nodes of a bottom up treestructure representing an oil recovery system, a single rig therein, oran equipment in an oil rig, wherein the nodes carry the results to thetop for easy visualization and use. The present invention also providesa dynamic reporting protocol for data transfers from an oil rig to acentral server wherein level identifiers are provided to transfer dataand its structure in a single packet transfer, thus enabling dynamicdata base population and display of reports from an oil rig. The resultsare presented on a web page or reported to cell phones, computers,pagers, personal data assistants or otherwise affirmatively reportedother wise to appropriate personnel. In a preferred embodiment, reportsare acknowledged by a first recipient or a second recipient is selectedfor receipt of the report when the first recipient does not acknowledgereceipt, and so on, until a recipient has received and acknowledged thereport. Alternatively multiple recipients may simultaneously get thenotification.

The present invention is automatically scaleable and extensible due tothe modular and dynamic nature of its design. Tests can be easilycreated, added or deleted and parameters added or modified on an oil rigequipment test or Health Check without reprogramming or changing thecentral server's database population, data reporting and data displayapplications. The reporting can vary between broad coverage and specificcoverage, that is, a status report can included data for an entire oilrecovery system comprising over 100 oil rigs and/or specifically reportstatus for a single oil rig of interest concurrently.

The present invention provides early warning of potential and actualfailures and also provides confirmation of product performance andusage. A set of automated Health Checks and diagnostic tests is selectedto run in real time on an oil rig. Status from the test is reportedcontinuously via a communication link between the oil rig and a centralserver. The present invention provides insight and analysis ofequipment, processes and equipment usage on an oil rig. The presentinvention monitors alarms and parameter limits to assess necessaryaction and perform affirmative notification of appropriate personnel.

The present invention provides quick response, real-time monitoring andremote diagnostics of the automation and control systems running on oilrigs comprising a fleet of oil rigs or an oil recovery system to achievemaximum rig performance while maintaining optimum personnel allocation.A service center is connected to the oil rigs through an Internet basednetwork. System experts make real-time data and logged data from the oilrigs available for perusal and analysis in a central facility or atdistributed locations. The web site of the present invention providesaccess to current operational status as well as to historical operationand performance data for each of the rigs comprising an oil recoverysystem.

Health Check tests are configurable so that new tests can be created,added or deleted and parameters changed for execution at an oil rigwithout the necessity of programming. A simple user interface isprovided wherein a user at the central server or at an oil rig canselect a test from a library of existing tests, or create a new testusing a scripting language, natural language interface or pseudolanguage is provided which generates a script defining inputs, outputsand processing logic for a test. The script is compiled and sent to therig for addition to existing Health Checks running on the rig. The userinterface also enables modification or addition and deletion ofparameters associated with a Health Check or test.

Notifications can be an immediate message when a problem is detected oran advisory notification. The notification is sent to expert servicepersonnel associated with the central server or can be directed to aservice manager or local service person closest to the rig needingservice. For each rig and problem type, a particular person or servicepersonnel category is designated for receipt of a notification.Secondary and tertiary backup personnel and personnel categories aredesignated as a recipient for each notification. Affirmativenotifications must be acknowledged by the recipient so that the problemis acknowledged and someone has taken responsibility for the problem. Ifan affirmative notification is not acknowledged within a configurabletime period, then a secondary or tertiary recipient is notified untilthe problem is acknowledged. Reliability reports are generated by thepresent invention showing performance summaries for oil rigs, comprisingup time, response, problems detected and solutions provided. Thesereports provide an objective basis for formulating an evaluation of theHeath Check system's efficiency.

The results from a rig include processed inputs from the rig. Noprocessing is required at the central server, other than display,storage and alerts to appropriate personnel. The oil rig Health Checksand tests are configurable so no programming is required to implement anew test or change logic or parameters for an existing test. A fieldengineer or central server personnel can add a new test withoutrequiring a user to perform a programming change. The present inventionprovides a local or remote user interface, which provides a simpleinterface for describing a test and logic. The interface comprises aniconic presentation, pseudo language, script or a natural languageinterface to describe a test's input(s), processing logic and output(s).The user interface interprets a user's inputs and converts the user'sinput into a scripting language. The script language is compiled andsent to the rig on which the new or augmented test is to be performed.The new test is added to a library of tests from which a user may chooseto have run at a rig. Test modules can be deleted, added, parameterschanged, and updated from the oil rig, the central server or from aremote user via a remote access electronic device.

Turning now to FIG. 18, a preferred embodiment of the present inventionis shown illustrating a global overview 200 of all rigs comprising anoil recovery system. As shown in FIG. 18, a map pinpoints geographiclocations of the rigs in the system of interest. A web page display ispresented on a personal computer or PDA. The web page generated by thecentral server presents a geographic view of an oil recovery system. InFIG. 18, rig number 563 (70)2 and rig number 569 (707) are shown with ared status, indicating that a condition or reporting event of interesthas occurred at rig number 563 and number 569. Rig number 569 (706) isin Canada and rig number 563 (711) is in the United States. Rig number571 (709) has a yellow status and rig number 567 (708) has gray status.All other rigs shown in FIG. 18 have a green status. When a system userclicks on rig number 569 (707) or the Canadian region, the display ofFIG. 19 appears. FIG. 19 shows the Canadian region, which includes rignumber 569. Notice that rig number 570 has a green status is nowdisplayed on the more detailed Canadian region display. The green statusgeographical indicator for rig number 570 is suppressed and not shown inthe broader display of FIG. 18 so that the more severe red status of rignumber 569 would be immediately visible and evident on the display ofFIG. 18. Once a user implicitly acknowledges the red status for rignumber 569 by clicking on rig number 569, the present invention displaysthe less severe status of rig number 570. Thus, the more severe statusof rig number 569 bubbles up in the geographical display and isdisplayed first at a higher level in the geographical display hierarchy.Note that the green status indicator of rig number 570, however, isshown in the panel 704 of FIG. 18 and FIG. 19. Thus, the presentinvention presents a hybrid display in which all Health Check resultsare available in the panel 704, but worst case results are presented inthe geographical displays of FIG. 18 and FIG. 19.

Turning now to FIG. 20, the status display 724 of FIG. 20 for rig number569 is shown when a user clicks on rig number 569 in FIG. 18 or FIG. 19.FIG. 20 illustrates that a rig number 569 component, “RigSense” has ared indicator. The Magnifying Glass icon 722 shown adjacent redindicator 730 indicates that more information is available regarding thered indicator 730. Notice that there are also additional panel displays716 and 718, which are configurable, which perform additionalinformative functions. A summary panel 720 is displayed for rig number569. The summary status panel contains operator reports from the oilrig. These operator reports are useful in diagnosing status andformulating a plan of action or notification. An AutoDriller statuspanel is also displayed. Note that the Weight on Bit (WOB) indicator 717is red in the AutoDriller status panel. A driller adjustable parameterspanel 718 is also displayed.

Turning now to FIG. 21A, continuing with rig number 569, clicking on thered indicator for RigSense status in FIG. 20, brings up the display forthe RigSense system panel status 740 as shown in FIG. 21A. Note that thedevice message block 743 may contain a part number to expedite repair ofa failure as reported. The particular part number and or drawing numbernecessary to perform a given repair associated with a given problem orseverity report may be difficult to find in a vast inventory of partsand part numbers and drawings associated with a given failure.Otherwise, the recipient of a failure report may have to search via keywords through a vast inventory of parts, part numbers and drawingsassociated with a given failure. Moreover, the user may not be familiarwith a particular vendor's part numbering system, thus, provision of thepart number is a valuable expedient to trouble shooting.

FIG. 21A shows that the sensor group device status 742 is red with aMagnifying Glass icon 746 indicating that more information is availablefor the red sensor group device status indicator 742. In an alternativeembodiment, as shown in FIG. 21B, a pop-up message 746 a appears alongwith the Magnifying Glass stating “Click on Magnifying Glass for moredetails.” Clicking on the red sensor group 744 device Magnifying Glass746 brings up the display 750 of FIG. 22, showing a detailed status forthe sensor group device status. Note that there are two red indicatorsshown in FIG. 22 for device status in the sensor group as follows: “Pump3 Stroke Count Sensor” 756 and “Hookload Sensor” 754. Note that the Pump3 red device status indicator has an informational comment 752 in theoperation column of the display of FIG. 22, stating “Intermittent Lossof Signal.” The Hookload Sensor red device status indicator present anadjacent Magnifying Glass icon 758 with a message indicating that moreinformation is available for the device status of the Hookload sensor byclicking on the Magnifying Glass icon. Clicking on the Magnifying Glassindicator 758 for the Hookload sensor brings up the Hookload sensorpanel 766 of FIG. 23, which shows that the device name “Barrier” 760 hada red device status indicator 762. The red device status for the Barrierdisplays an Operation message 764, stating, “Excessive ground current”.Each colored indicator and accompanying operation message shown in thepreferred displays illustrated in FIGS. 18-23 appeared in line of theHealth Check performed at an oil rig and sent to the server in thestructured protocol of the present invention.

FIG. 24 illustrates a Driller Adjustable parameters display 710 with twored indicators showing that Drill Low Set Point 712 and Upper Set Point714 are Outside Range. A Drilling Tuning parameters panel 716 is alsodisplayed. Both panels indicate the current value, changed indicator andoutside range indicator for each parameter displayed in the respectivepanels of FIG. 24. The display of FIG. 24 is an alternative tabulardisplay for rig status for a single rig. FIG. 25 illustrates aconfiguration or driller adjustable parameters status panel 810 for rignumbers 178-189. The display of FIG. 25 is an alternative tabulardisplay for rig status for plurality of rigs, e.g., rigs 178-189.Turning now to FIG. 26, a data acquisition system 801 is shown in an oilrig environment connected to a plurality of legacy or Heath Checksensors (“SENSORS”) which, in certain aspects, include sensors on ashaker or shakers, which gathers data from the group of sensorsmonitoring the rig equipment, parameters and processes. The dataacquisition system 801 sends the acquired data from the sensors to acomputer 804 on which the preferred Health Check application of thepresent invention is running. The application of the present inventionperforms Health Checks logic on the acquired data and reports theresults in the structured protocol to a user via satellite 806 or someother form of electronic communication. A user may monitor health checkstatus and receive notifications via an electronic receiver 808,diagnostic station 807 or mobile in field service vehicle 805.Alternatively the shaker(s) may have a direct connection from a shakercomputer CPR to the data transmission system.

The present invention is also useful for Process Monitoring, that is, todetermine that equipment is being used properly to perform a designatedprocess. For example, if rig operators are using an “override” during acertain system state indicative of a certain process, which is supposedto be run automatically rather than manually overridden, the presentinvention can perform a health check to detect this event of interestand report it to the central server. Knowledge of this occurrenceenables central server personnel to detect and correct the inappropriateaction of the operators. Moreover, the test to detect the inappropriateoverride stays in the system so that if new operators recreate theproblem or trained operators backslide into using the manual overrideinappropriately, the central server personnel will be notified so thatthe problem can be address again. Thus, the Health Check system builds acumulative base of operational checks to insure that a process on a rigor oil recovery system runs in optimal fashion.

Turning now to FIG. 27, FIG. 27 is an illustration of a preferred HealthCheck system reporting health checks of multiple equipments, processesor systems from multiple oil rigs to multiple users. It is to beunderstood that any equipment's, device's, or apparatus's controller orassociated computer may be employed for the system as shown in FIG. 27,but the specific item shown schematically is a controller and/orcomputer for a shaker. As shown in one aspect the shaker controllerand/or computer is in communication with a Rig Health Commander, aHealth Check Engine, and a user. Optionally, the shaker controllerand/or computer can be in direct communication via the Internet or asimilar network with another entity, device, and/or user.

Turning now to FIG. 28, the results of the tests are reported to thecentral server in a special protocol that contains heath check resultsdata and describes the manner in which the data is constructed so thatthe data can be placed in a logical data structure or tree format anddisplayed. Note that the root node 810, usually an oil rig has adesignation of “00”. The first level of nodes 812, 813 etc. under theroot node are named Aa, Ab, Ac, Ad, etc. Each subsequent layer of nodeis named with the name of the parent node followed by a designation ofthe current node. For example, as shown in FIG. 28, for a rig number569, the root node 810 is named “00”, the first level of children nodesunder the root node are named Aa 812 and Ac 813. The children of node Aa812 are named AaBa 814, AaBd 1116, AaBe 818 and AaBf 820 as shown. Thechildren of child node AaBa are named AaBaC1 822, AaBaC2 824, AaBaC3 826and AaBaC4 828. The children of node AaBaC5 830 are named AaBaC5Dg 832,AaBaC5Dp 834, AaBaC5Dq 836 and AaBaC5Ds 838. A new test could be addedto rig 569 number and the Heath Check status could be reported undernode AaBaC5Dx 839.

Changes to the Health Checks running on any or all rigs does not requirechanges to the display or data base population application because thepreferred communication protocol defines the data base layout anddisplay layout. The leaf nodes of the tree structure represent HealthCheck results. Each node contains a test identifier, test result(red/yellow/green/gray), intermediate data, user-entered data and testdescription. Trouble shooting comments are provided at the centralserver based on reported errors. Test error codes are included in thenode so that messages associated with the error codes are displayed tothe appropriate user. Alternately, trouble shooting and otherinformation can also be generated and appended to the results of thetests at rig site. Thus, no processing to determine rig status is doneat the central server. Notifications are sent when deemed necessary bythe application. Notification logic is configurable by service personnelat the central server or at the oil rig. Notification logic dictatesthat notifications are sent when an event occurs and the event has beenselected for reporting as a notification to a user. The notificationlogic and a list of appropriate notification recipients in order ofpriority, that is, who to contact first, is retained at the centralserver. The event can be a report on an equipment status, processexecution or an operational item. A user can check in with the centralserver of present invention to obtain a real time report of the statusof an oil rig or multiple oil rigs. The requesting user will receive aseverity report message indicating the status of the rig, for example,“okay” or “red/yellow/green/gray.”

FIGS. 29-32B illustrate computer screen displays for one embodiment of acontrol system for shakers and methods of their use according to thepresent invention.

FIG. 29 shows a display screen provided by a server, e.g. a web serveron a computer on a shaker (e.g. like the computers 530, 630 and theshale shaker computer controller in FIG. 27). When this computer isconnected to and in communication with a rig control system, interfaceswith the rig control system are identified as “Alarms & Events,”“Diagnostics,” and “Documentation.” From the “General” column, anoperator can go to any of the five listed choices. Choosing “DebugMonitor” leads to a display screen as in FIGS. 32A and 32B that allows auser to monitor and modify shaker program variables. Choosing“Administration” leads to a display screen as in FIG. 30. “ArrayManipulator” leads to a screen that shows the array of input/outputchannels. “Software versions” leads to a screen that displays thecurrent software version. “Log Manager/Viewer” leads to a screen thatallows the user to view and delete system log files.

The display screen of FIG. 30 (displayed by clicking on the “DebugMonitor” line, FIG. 29) illustrates a variety of administrative checksand tasks that can be done related to the shaker computer. “Restart JVM”is chosen to restart the computer software operating system on theshaker computer. The shaker control program is stopped by choosing “StopController.” This screen lets a user choose which parameters andvariable are viewed (e.g. in screens like screens in FIGS. 32A and 32B).The general state of the shaker is displayed by choosing“ControlStation.” Choosing “Timer” displays timer variables and states.The “ai” screen displays analog input variables and states, e.g. fromthe ultrasonic transducers, the measured distance to fluid on thescreens. Controller variables and states are displayed by choosing“controller.” Digital input variables and states [e.g. signals from ashaker's variable frequency drive] and those effected using user pushbuttons and switches (e.g. as in FIG. 14) are displayed by choosing“di.” Digital output variables, e.g. valve opening and closing signalsand signals to a VFD to run fast or fun normal, are displayed bychoosing “dq.” Parameters and variables of the protocol used to send andreceive information is displayed by choosing “modbus.”

In FIG. 32A the entries indicate the following: Entry IndicationactuatorState state of actuator (e.g. 636, FIG. 14) - moving up, movingdown, stopped autoOrManualModeState auto control or user control ofbasket angle fluidLevelState pool depth on screen relative to desiredposition - high, low, desired fluidFlowState relative fluid flow rateonto shaker screens basketAngleState basket angle - home position,intermediate, high commandState command output sent to actuator system -main timer waiting, null, actuator moving up, actuator moving downcontrolState state of sensor reading timer cycle - waiting, readingfluidFlowNoFlowCounter number of consecutive times fluid flow sensor hasmeasured a no- flow fluidFlowNoFlowMaxCount preset number of consecutivetimes flow sensor must measure no-flow before basket angle is moved tofully uphill position to prepare for next fluid rush sensorReadCountercurrent number of times sensors have been read sensorReadCounterMaxCountnumber of sensor readings to take, filter, and return a signal valuemotorMotionState current shaker motion - linear, elliptical, circularmotorSpeedState speed of shaker motors - normal, boostboostConditionsMetCounter number of consecutive times boost conditionshave been met boostConditionsMetCounter number of consecutive timesboost Max conditions must be met before motor speed is automaticallyboosted fluidLevelDataState indication whether sensor reading are withinexpected range - in scope, out of scope fluidLevelValidSensor indicates% of sensor reading DataPercentage within expected rangefluidFlowDataState whether sensor readings are within expected range -in scope, out of scope fluidFlowValidSensor indicates s$ of sensorreading DataPercentage within expected range

In FIG. 32B, the entries indicate the following for each of threedifferent sensors (ultrasonic transducer apparatuses): Entry Indicationdeadband distance above or below desired value that will not cause theactuator to move desiredValue desired fluid level fluidLevelErrordifference between desiredValue and fluidLevel_inches fluidLevelInchesdistance that represent fluid level homePosition distance to the bottomof the screen at the lowest basket angle maxValueFiltered maximumallowable filtered fluid level (medianDistance) medianDistance filteredfluid level minValueFiltered minimum allowable filtered fluid level(medianDistance) offset distance above the homePosition that representsa high flow runningState pool depth on the shaker screen relative to thedesired position - high, low, at desired validSensorDataPercentage the %of sensor readings within the expected range validSensorDataPointsactual number of valid sensor readings calibrateCommand has thecalibrate button been pushed decoded is the input used forceEnabled isthe input value controlled by the Debug Monitor forceValue value toforce the input to if forceEnabled is true ioIdentifier Modbus addressof the input ioType (MOD) Modbus protocol maxRawValue maximum value thatcan be returned from the input maxValue measurement scale valuecorresponding to the maxRawValue for this input minRawValue minimumvalue that can be returned from the input minValue measurement scalevalue corresponding to the minRawValue for this input rawValue rawinteger value returned from the input

The present invention, therefore, in at least some, but not necessarilyall embodiments, provides a vibratory separator including: a base; abasket movably mounted on the base and for supporting screen apparatusfor treating material introduced into the vibratory separator, thebasket on the base and pivotable with respect thereto; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; vibratory motor apparatus connected to the basket forvibrating the basket and the screen apparatus; variable frequency driveapparatus for selectively driving the vibratory motor apparatus at aselected speed; angle adjustment apparatus connected to the basket foradjusting angle of the basket; sensor apparatus connected to thevibratory separator for sensing a parameter indicative of operation ofthe vibratory separator for providing a signal corresponding to saidparameter; and control apparatus for receiving signals from the sensorapparatus, for controlling the vibratory separator based on saidsignals, and for automatically signalling the variable frequency driveapparatus to change the speed of the vibratory motor apparatus so thatforce applied to the basket is changed. Such a vibratory separator mayhave one or some (in any possible combination) of the following: whereinthe basket is tilted at a largest possible uphill angle; wherein thecontrol apparatus includes timing apparatus that indicates the baskethas been maintained at the largest possible uphill angle for a pre-settime period and actuation apparatus for actuating the variable frequencydrive apparatus to increase the speed of the vibratory motor apparatusupon said pre-set time being achieved; wherein said actuating is donefor a pre-set period of time or until a pre-set flow of material to thematerial introduction end is sensed by the sensor apparatus; wherein thevibratory separator is a shale shaker and the material is drilling fluidwith drilled cuttings therein; wherein the vibratory apparatus comprisestwo motors for vibrating the basket, the two motors providing dualmotion capability; wherein the sensor apparatus comprises a plurality ofsensor apparatuses; wherein the measurement sensor apparatus is from thegroup consisting of electrical, optical, electromagnetic, ultrasonic,acoustic, and pulse-echo apparatus; flow sensor apparatus connected tothe vibratory separator for sensing the flow of material onto the screenapparatus, the flow sensor apparatus controlled by and in communicationwith the control apparatus, and the control apparatus for adjustingshaker operation in response to signals from the flow sensor apparatus;the vibratory motor apparatus connectible to the basket at a pluralityof locations so that a motion profile of the basket is selectivelyvariable between linear, elliptical, and circular motion; wherein themotion profile of the basket includes a first shape at a materialintroduction end of the basket and a second shape at a material exit endof the basket; wherein the basket has a middle area between the materialintroduction end and the fluid exit end and the motion profile of thebasket includes a thin ellipse shape at the material introduction end, amedium ellipse shape at the middle area, and a fatter ellipse shape atthe material exit end; the vibratory motor apparatus including bearingapparatus for enhancing operation of the vibratory motor apparatus, thesensor apparatus including temperature sensor apparatus for sensingtemperature of the bearing apparatus during operation, and the controlapparatus for providing a notification to an operator of the vibratoryseparator that the bearing apparatus is to be greased; the controlapparatus for monitoring total operational time of the vibratoryseparator and for providing a notification of said total operationaltime; the control apparatus including web interface apparatus for aninterface between on-site personnel at a location of the vibratoryseparator and an entity remote therefrom; the vibratory separator on adrilling rig, the control apparatus for monitoring and analyzing aplurality of signals from the sensor apparatus and for transmittingsignals indicative of information related to operation of the vibratoryseparator to a processor on the drilling rig, the processor including aset of health check rules for health checks comprising logical rules,inputs and outputs for defining events associated with the status of thevibratory separator, the processor for determining a severity code foreach event and for reporting the events and severity codes to a centralserver, the events reported by the processor to the central server in aprotocol defining a data structure, the data structure comprising ahierarchical tree node structure wherein results from application of thehealth check rules are a bottommost node of the tree node structure, anddisplaying the event severity codes on a display; the processor forproviding to the central server the results as records containing nodeinformation regarding an appropriate location for the results in thetree node structure; and/or the control apparatus running the healthchecks in real time to provide results regarding on-going status of thevibratory separator to indicate a potential failure of the vibratoryseparator.

The present invention, therefore, in at least some, but not necessarilyall embodiments, provides a vibratory separator including: a base; abasket movably mounted on the base and for supporting screen apparatusfor treating material introduced into the vibratory separator, thebasket on the base and pivotable with respect thereto; screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment; vibratory motor apparatus connected to the basket forvibrating the basket and the screen apparatus; sensor apparatusconnected to the vibratory separator for sensing a parameter indicativeof operation of the vibratory separator for providing a signalcorresponding to said parameter; control apparatus for receiving signalsfrom the sensor apparatus, for controlling the vibratory separator basedon said signals; wherein the vibratory separator is a shale shaker andthe material is drilling fluid with drilled cuttings therein; whereinthe sensor apparatus comprises a plurality of sensor apparatuses; andthe vibratory motor apparatus connectible to the basket at a pluralityof locations so that a motion profile of the basket is selectivelyvariable between linear, elliptical, and circular motion.

The present invention, therefore, in at least some, but not necessarilyall embodiments, provides a method for treating material introduced to avibratory separator, the method including introducing material to avibratory separator according to the present invention, treating thematerial in the vibratory separator, and adjusting the angle of thebasket, its motion profile, and/or its motor speed.

FIGS. 33-35 show a shale shaker 470 according to the present inventionwhich has a screen-mounting basket 472 and a bridge 474 on which aremounted two vibrating apparatuses 480. The basket 472 has brackets 476to which are secured helical springs 478. Each spring 478 is secured toa base member 482. As shown in FIG. 35, an optional housing 484 may beused on sides of and beneath the shale shaker 470. Optionally (and asmay be the case with any shale shaker disclosed herein according to thepresent invention or with any known prior art shaker or vibratoryseparator) an electronic tracking apparatus 489 is on the housing 484,but may, according to the present invention, be within any suitablemember or part of a shale shaker; and, optionally, such a trackingapparatus has a container or housing made of composite material and/oris encased within or coated with composite material. Any known trackingdevice, apparatus, or system may be used, including, but not limited toknown satellite tracking systems.

The brackets 476 are made, in one aspect, of composite material, as arethe base members 482 and the housing 484. Optionally, the basket 472(side walls 472 a, 472 b; ends 472 c, 472 d) is made of compositematerial. Alternatively one, some, or all of these components are madeof steel encased in composite or steel coated with composite. A coatingof composite may have the thickness of a layer of paint or of two,three, four or more layers of paint. A shale shaker similar to the shaleshaker 470, but with no teaching, motivation, or suggestion of usingsuch composite material for a shale shaker or parts of it, is disclosedin U.S. Pat. No. 6,155,428 incorporated fully herein for all purposes.

FIG. 36 shows a shaker 570 according to the present invention. Material570 m to be treated (e.g. drilling fluid with solids) by the shaker 570is introduced from a tank 571. Material and fluid flows onto screeningapparatuses 573, 572, and 574 which are mounted in a shaker basket 576.Any of the screening apparatuses 573-575 may be horizontal (see thescreening apparatus 573 FIG. 36) or inclined uphill (see the screeningapparatuses 572, 574, 575). Vibratory apparatus 577 vibrates the basket576 and the screen apparatus 572-575. Electromagnetic vibratoryapparatus (e.g. as in FIG. 43A or FIGS. 44A-44C) may be used instead of(or in addition to) the apparatus 577. A flowback pan 574 a under thescreening apparatus 574 receives fluid flowing through the screeningapparatus 574 which flows down to a container 578. A flowback pan 575 adirects material to the screening apparatus 575.

Material and/or fluid flowing through the screening apparatuses 572-575flows down into a sump, tank or container 578. The basket 576 is mountedon a frame with springs (not shown). Material not flowing through thescreening apparatuses, e.g. separated out solids, flows off the end ofthe screening apparatus 574 down onto the screening apparatus 575.Material 570 r separated out by the screening apparatus 575 flows on topthereof and off the end thereof.

The screen apparatuses 572-575 may be any known screens or screenassemblies used with vibratory separators or shale shakers.

Each screen apparatus 572-575 has an energizable identificationapparatus or apparatuses 573 i-575 i, respectively, therein or thereonand/or the shaker 570 has an energizable identification apparatus orapparatuses 570 i therein and/or thereon. Any energizable identificationapparatus disclosed herein may be used for the screen apparatuses (andfor any disclosed herein), vibratory apparatus (and for any disclosedherein), and/or for the shaker (and for any disclosed herein)(including, e.g. RFIDT's and/or SAW's). Optionally, the vibratoryapparatus 577 has an energizable identification apparatus 577 i thereinor thereon and/or motor weights 577 m have an energizable identificationapparatus 577 p. An energizable identification apparatus disclosedherein for a screen or screen assembly may contain any desiredinformation and may be a read-only or read-write apparatus. Suchinformation may include, but is not limited to: date and place ofmanufacture; manufacturer identity; frame or support type and material;screening material type, material, weave, mesh count; material used forbonding, welding, gluing, connection or adhesion; screen size,dimensions; whether or not refurbished or remanufactured; heattreatment(s); metallurgy; time in service; wire diameter; framedimensions; and type of side mounts. Any reader apparatus or systemdisclosed herein may be used to read and monitor the apparatus 570 i.

As is the case with several screens on various shale shakers, thescreens 572, 574, and 575 are inclined so that materials thereon mustclimb “uphill” to exit off the end of the screen. It is within the scopeof the present invention to use an energizable identification apparatus(any disclosed herein) with any such inclined screen, with flat(horizontal) screen(s) and with any inclined screen, or non-downwardlyinclined, on any vibratory separator or shale shaker.

Optionally the shaker 570 is provided with a reader apparatus 579, onthe shaker or adjacent thereto, (e.g. as any disclosed herein or in theprior art) to read and monitor the energizable identificationapparatuses on screens mounted on the shaker 570 and/or on other partsof the shaker 570. Optionally, the reader apparatus communicates with acontrol system 579 a (on site or remote). The control system 579 acontrols the vibratory apparatus 577 (motor, motors; or electromagneticvibratory apparatus) and can monitor all the energizable identificationapparatuses. With respect to a particular screen assembly, the controlsystem 579 a receives signals, including identification signals, fromenergizable identification apparatus on a screen assembly and thecontrol system (or any interconnected computer system 579 c, on site orremote) determines whether that particular screen assembly is suitablefor use on the shaker 570. If via sensors 570 s the control systemdetermines that the particular screen assembly is not suitable for thematerial being processed and/or for particular flow rates, the controlsystem and/or computer system can send a signal and/or an alarm and/orcan automatically shut the shaker down. Signals from the energizableidentification apparatus 577 i can indicate, e.g., motor manufacturingdate, last service date, motor refurbishment date, etc. Signals from theenergizable identification apparatus 577 p can indicate nominal ratedmotor force so the control system can ensure correct motor forceoperation at correct frequency and operation.

FIG. 37 shows a screen assembly 790 according to the present inventionwhich has a frame 791 with crossmembers 793 a and cross rods 793 b withmultiple screen mesh layers 792, 794, 796. Epoxy material connects themesh layers to the frame 791.

An energizable identification apparatus 795 on an exterior portion ofthe frame 791 with a protective tape, covering or encasement 798 (whichmay be encasement, layer(s), mass of material, tape(s), and/or wrapsdisclosed or referred to herein) Optionally, a protective covering,etc., encircles the portion of the frame 791 adjacent the apparatus 795.Optionally, or instead of the apparatus 795, an energizableidentification apparatus 797 is on an inner portion of the frame 791 andis protected by an encasement, tape, or protective covering 797 (whichmay be any encasement, tape(s), layer(s), mass of material, and/orwrap(s) disclosed or referred to). It is within the scope of the presentinvention to provide one or more apparatuses 795 and/or one or moreapparatuses 797 on or in any portion of any screen or screen assemblyused with a vibratory separator or shale shaker, including but notlimited to, on frames, plates, supports, lips, ledges, crossmembers,rods, structural parts, and seal structures of such screens or screenassemblies.

FIGS. 38A-38D show a screen assembly 840 according to the presentinvention which has a tubular frame 842 made of hollow tubulars withends 844 and interconnected sides 845. A screening material layer orcombination of layers 850 is secured to the tubular frame 842 withsuitable glue and/or adhesives. A plurality of spaced-apart crossmembers843 extend between and have ends 844 connected to the sides 845. Thescreen assembly 840 may, in one particular aspect, have a multi-layercombination 850 of layers of screening material adhered together withadhesive or epoxy or glued together with moisture curing hot melt gluein a glue pattern 862.

It is within the scope of the present invention to position and/or mountan energizable identification apparatus within any part of a screen orscreen assembly for a vibratory separator or shaker, including, but notlimited to, within a hollow frame member or tubular, within a hole orrecess, or within a side mounting structure of a screen or screenassembly. The screen assembly 840 has an energizable identificationapparatus 841 secured in an amount of material 846 (e.g., plastic,epoxy, fiberglass, gel, aerogel, silica aerogel, wood, metal, composite)within an end 844 of the screen assembly 840 and an energizableidentification apparatus 847 in an amount of material 847 a within aside 845. Energizable identification apparatus 848 and 849 areadhesively secured exteriorly to parts of the frame 842 and/or have alayer or layers (not shown) of encasement or tape 848 a, 849 a overthem.

Often identification tags or labels, e.g. made of plastic or metal areused on screens and screen assemblies to convey information about thescreen or screen assembly. It is within the scope of the presentinvention to include on or within such labels or tags one or moreenergizable identification apparatuses. For example, a tag or label 851on the frame 842 (FIG. 38D) has information 852 about the screen 840 andon or embedded within the tag or label 851 is an energizableidentification apparatus 853.

FIGS. 39A-39D show a screen assembly 910 according to the presentinvention which has a layer or layers 912 of screening material and sidemounts 914. In one particular aspect there are three layers 912 ofstainless steel screening material with a lowermost layer with mesh of20×20, a middle layer of 105×64 mesh, and a top layer of 170×105 mesh.It is within the scope of this invention for the layers 912 (as with anylayers of any screen or screen assembly disclosed herein) to be anyknown screening material separate and unconnected to each other or withlayers bonded, connected, fused, sintered, glued together, and/or sewntogether in any known manner and the screening material may be made ofany known material used for such screen assemblies.

In certain aspects, the layers 912 of screening material (as with anylayers of any screen or screen assembly disclosed herein) are gluedtogether with cured hot melt glue producing glued-together screeningmaterial that is flexible. In some aspects a screen assembly accordingto the present invention with flexible material can be folded on itselfor rolled up.

Each side mount 914 has a bottom part 921, a side part 922, a top part923, a top lip 924, and a top lip 925. The layers 912 pass between andare secured between the bottom part 921 and the top lip 924. An end ofthe layers 912 is held between opposed parts 925 a and 925 b of the toplip 925. The top lip 924 may, optionally, be adhesively secured togetherand/or welded to the bottom part 921 with multiple spaced-apart welds926 along the length of the side amounts 914. Similar adhesive materialand/or welds may be, optionally, used along the top lip 925. In otheraspects, the welds 926 are deleted or are supplemented with glued areasalong the mounts 914. Alternatively, or in addition, inwardly projectingteeth or humps on the top lip 924 and/or bottom part 921 may be used tohold screening material. The bottom part 921 has a plurality ofspaced-apart holes 929 for receiving corresponding upwardly-directedprojections of a screen mounting structure or apparatus of a shaleshaker or vibratory separator. Optionally ends 916 of the side mounts914 are sealed with any suitable seal material or seal structure. Asshown in FIG. 39D, a solid plug or an amount of hardened adhesive or hotmelt glue 927 is applied at the end opening 916. An energizableidentification apparatus 928 is encased within the plug 927. Optionally,such material may encapsulate the edge of screening material layers 912.In certain aspects the side mounts and/or the plug 927 are made ofplastic, epoxy, acrylic, steel, stainless steel, fiberglass, composite,aluminum, aluminum alloy, zinc, zinc alloy, brass or bronze. Optionallythe top part 923 is deleted and a generally “L” shaped side mount isprovided and it is within the scope of this invention to provide such aside mount with any seal or handling apparatus described herein.

Optionally, a plurality of screws 931 secure a seal member 930 to theside part 922. In one aspect the seal member 930 is (as may be the casefor any seal or seal member according to the present invention) made ofneoprene, but it may be made of nitrile rubber, rubber, plastic, gasketmaterial, polyurethane, or any suitable seal material. The seal member930 has an upper portion 932 of generally circular cross-section (but,according to the present invention, this cross-section may be anydesired shape, including, but not limited to, square, oval, andrectangular). Optionally, the upper portion 932 is hollow and, e.g. mayhave a space 933 of a generally circular (or of any desired shape)cross-section. An elongated part 934 of the seal member 930 extends downfrom the upper portion 932. The seal member 930 is, in one aspect,positioned so that when the screen assembly 910 is in place on a shaleshaker or vibratory separator, the seal member 930 is trapped betweenthe screen assembly 910 and the side wall of a basket or other screenholding structure. In another aspect the seal member 930 is positionedso that the upper portion 932 is above a top edge of the top lip 925.The seal member 930 may be adhesively secured to a side mount. Anenergizable identification apparatus may, according to the presentinvention, be in or on the seal member 930 or in the hollow part of theend 932.

FIG. 40 shows a screen assembly 940 according to the present inventionwhich has side mounts 944 (like the side mounts 914, FIG. 39D); one ormore layers 942 of screening material (like the layer or layers 912 ofthe screen assembly 910); and one, two, three or more layer(s) 946 ofridged or undulating screening material on and/or connected to thelayer(s) 942. The screening material layer(s) 946 may be any knownundulating or ridged screening material, including, but not limited to,that disclosed in U.S. Pat. Nos. 6,450,345; 5,868,929; 5,720,881;5,958,236; 5,876,552; 5,636,749; 5,417,858; 5,417,793; 5,417,859; and5,944,993, all fully incorporated herein fully for all purposes. In thescreen assembly 940 a portion of the layers 946 may pass with thelayer(s) 942 between the bottom part and lower lip of the side mounts944 and, if desired, into the top lip. Alternatively only the layer(s)942 are secured within the side mounts 944. The side mounts 944 may havean energizable identification apparatus 944 a like the energizableidentification apparatuses shown and/or described for the embodiment ofFIG. 39D.

FIG. 41A shows a screen 1110 according to the present invention with alower base, support or frame 1112, three undulating mesh screens 1114(any two of which may be deleted) on and/or bonded or connected to theframe 1112, and, optionally, an upper mesh or screen 1116. The screens1114 may themselves be sewn, bonded or glued together, e.g. with epoxy,glue, welding, and/or sintering. Rubber strips, plastic strips tape,cushion or cushions 1118 are positioned between the screen 1114 and theupper screen 1116. The strip(s) or cushion(s) 1118 are optional. Asshown the strip(s), tape(s), or cushion(s) 1118 are secured to thescreen 1114 (or to crests thereof), but it is within the scope of thisinvention to secure them (or some of them) to the screen 1116. To effectsuch securement any suitable glue, epoxy, weld, and/or sintering may beemployed. The frame 1112 may be any suitable known base, frame orsupport.

It is within the scope of this invention for the screen 1114 to be anyknown screen, mesh, screens, meshes, or combination thereof, bondedtogether, unbonded, or bonded at only certain locations and with anyknown shape as viewed either from above or on end (as in FIG. 41A). Itis within the scope of this invention for the upper screen 1116, whichis optional, to be any known screen, mesh, screens, meshes, orcombination thereof, bonded together or unbonded, and with any knownshape. As shown in FIG. 41B, the screen 1114 is three mesh screensbonded together with coarser mesh on the bottom, medium mesh in themiddle, and finer mesh on top. The screen 1116 as shown may be ascalping screen of a mesh coarser than the finest mesh of the screen1114 or of a multi-layer coarser mesh. In another aspect the screen 1114is a single screen of closely woven mesh made of any suitable material,e.g. stainless steel and/or plastic material and the screen 1116 is asingle screen of coarser mesh made of any suitable material (e.g. butnot limited to stainless steel and/or plastic), with the screen 1114 ona metal or plastic frame or support. Alternatively or additionally,instead of the frame 1112 any known perforated plate, strip, support, orseries of straps or strips may be used.

In one aspect the strips 1118 are fused plastic strips aligned withpeaks of the undulating fine mesh. Such strips may be made of rubber(e.g. nitrile) or plastic, e.g. polypropylene, to inhibit or preventabrasion of the finer meshes. Such strips can be glued to the bottom ofthe screen 1116 and/or the screen 1114. Also the screen 1116 can beglued to the screen 1114.

End plugs 1113 and 1115 (FIG. 41D) sealingly close off open ends of thescreen 1110. These end plugs may be made of rubber, metal, wood,plastic, Teflon™ material, or urethane. The plugs 1113 extend along twosides of the screen along crests of the screening material to completelyseal the sides. The plugs are held in place by friction fit, glue,epoxy, welding and/or sintering. Alternatively, the ends may be coveredwith screen material.

Fluid flow on the screen 1110 from either end may be from top-to-bottomas viewed in FIG. 41A, bottom-to-top, or from one side to the other.

In one aspect the screen 1116 is a scalping screen of woven steel mesh.In another aspect, it is woven plastic or synthetic or composite mesh;and in another aspect it is a combination of woven steel and wovenplastic or synthetic or composite mesh. The screen 1116 may be the samemesh or coarser mesh than that of the screen 1114 or of any layerthereof.

In one embodiment the areas 1117 between the screen 1116 and the screen1114 are open. The screen 1116 protects the mesh of the screen 1114 fromabrasive particles. When the screen 1116 is of a coarser mesh than thatof the screen 1114, relatively larger particles retained on the screen1116 are prevented from damaging and/or hindering flow through thescreen 1114.

With the screen 1110 as shown and with the optional screen 1116 liquidflow through the screen is increased by reducing the thickness of thesolids bed of the finer mesh screens by the separation of largerparticles with the screen 1116.

FIG. 41E shows an alternative embodiment of the screen 1110 withidentical parts (indicated by the same numerals) but with additional endplugs 1119 between the upper screen 1116 and the screen 1114. Such“double plugging” may be used on either or both screen ends. A fluidand/or particles introduced to the screen 1110 first encounters thescreen 1116 and then material flowing through the screen 1116 flows tothe screen 1114. The plugs 1119 may be made of the materials describedfor the plugs 1113, 1115 and the plugs 1119 may be similarly installedand/or secured in place. Any of the plugs 1113, 1115, 1119 may bedeleted in certain embodiments.

As has been described previously, any previously-disclosed energizableidentification apparatus may be applied to any part of the screen 1110.An energizable identification apparatus 1120 is embedded within a plug1115 and/or an energizable identification apparatus 1122 is embeddedwithin a plug 1113. Optionally, an energizable identification apparatus1124 is embedded within a plug 1119 (FIG. 41E).

Optionally, an energizable identification apparatus 1126 with an antenna1127 extending therefrom is located within the frame 1112. It is withinthe scope of the present invention when an energizable identificationapparatus being used has an antenna extending therefrom, to adhere theantenna to part of the screen or screen assembly and/or to locate theantenna within part of the screen or screen assembly (e.g. within aframe member, seal, hookstrip, or side mount) and/or to locate such anantenna in a mass of material.

FIGS. 42A and 42B show a screen assembly 950 according to the presentinvention which has a lower support plate 952 and one, two, three, fouror more layers of screening material on the plate 952 (three layers 953,954, 955 shown). Side hookstrips 956 on sides of the plate 952facilitate mounting of the screen assembly 950 to a deck or mountstructure of a vibratory separator or shaker. An energizableidentification apparatus 957 is secured to an exterior portion of ahookstrip 956 and/or an energizable identification apparatus 958 issecured to an interior portion of a hookstrip 956. In one particularaspect the screen assembly 950 is like a screen assembly disclosed inU.S. Pat. No. 4,575,421 (incorporated fully herein) modified in accordwith the present invention.

According to the present invention an energizable identificationapparatus (any disclosed herein) can be applied to, connected to, ordisposed within a screen assembly using a solid mass within which islocated the energizable identification apparatus. FIG. 42C shows a mass951 of material within which is an energizable identification apparatus959. The mass 951 is sized and configured for insertion into a recess,notch, hollow, channel or opening of a screen assembly (or otherapparatus) to facilitate installation of the energizable identificationapparatus 959. The mass 951 can be held in place with a friction fitand/or adhesive, glue, welding, and/or tape and/or any layer(s), wrap(s)or encasement disclosed herein. The material of the mass 951 can bemetal, plastic, composite, wood, ceramic, cermet, fiberglass, gel,aerogel, silica aerogel, nonmagnetic metal, or polytetrafluorethylene.The material can be rigid and relatively unbending or it can be softand/or flexible. An enlarged end 951 a of the mass 951 is optional, asis the conical shape of the mass 951 (any desirable or convenient shapebeing within the scope of the present invention, including but notlimited to cubic pyramidal or any regular solid).

FIG. 42D shows a mass 1151 (made, e.g. of any material mentioned for themass 951) with an energizable identification apparatus 1159 therein. Theenergizable identification apparatus 1159 has an antenna 1158 extendingfrom the energizable identification apparatus 1159 and disposed withinthe mass 1151. With a flexible or sufficiently non-rigid mass 1151 (andwith a flexible mass for the mass 951) a slit or recess 1157 of anydesired length and extent within the mass 1151 may be provided forinserting the energizable identification apparatus 1159 and antenna 1158into the mass 1151 and/or for removable emplacement of the energizableidentification apparatus 1159.

FIG. 42E shows a mass 1141 (e.g. like the masses 951, 1151 and made ofthe materials mentioned above) with an energizable identificationapparatus 1142 therein (or it may, according to the present invention,be thereon). The mass 1141 has a recess 1143 sized, located, andconfigured for receipt therein of a part or a portion of a screen orscreen assembly so that the mass 1141 is easily installable on a part(e.g. a frame part, crossmember, or edge) of a screen or screenassembly. A friction fit between the mass 1141 and the part or portionof the screen assembly can hold the mass 1141 in place (e.g. on a frame,part, edge, rod crossmember, plate, mount, hookstrip, or support of ascreen or screen assembly) and/or connectors, fasteners, releasablycooperating hook-loop material, and/or adhesive may be used to hold themass 1141 in place (as is true for any energizable identificationapparatus disclosed herein).

FIGS. 43A-43E show a shale shaker 1200 according to the presentinvention which has a base 1202 with a fluid input tank 1204 from whichdrilling fluid with solids therein is fed to a screen assembly 1210.Drilling fluid passing through the screen assembly 1210 flows down andmaterial (including undesirable solids such as drilled cuttings) movingup the screen assembly 1210 (which is inclined “uphill”) moves off theend of the screen assembly 1210 and flows down onto a lower screenassembly 1220 which is also inclined “uphill.” Drilling fluid passingthrough the screen assembly 1220 flows to a pit, tank or collectionreceptacle 1208 and material (including undesirable solids such asdrilled cuttings) moves off the end of the screen assembly 1220 andfalls to a container or further processing apparatus.

The screen assemblies 1210 and 1220 are releasably mounted to decks1232, 1234 of a basket 1230. Two electromagnet apparatuses 1240 aremounted on a support 1242 which is, optionally, secured to the base 1202with springs 1244. Plates 1243 secured to a mounting bracket 1246(which, in one aspect, is made of composite material) which is securedto the basket 1230 are attracted by the electromagnetic apparatuses1240. Each electromagnetic apparatus 1240 has a mounting bracket 1240 a(which, in one aspect, is made of composite material) By pulsing powerto the electromagnetic apparatuses 1240 (e.g. with alternating current),the plates are moved quickly toward and away from the electromagneticapparatuses 1240, thus vibrating the basket 1230 and the screenassemblies 1210 and 1220.

An alternating current applied to the electromagnet causes an attractiveelectromagnetic force between the electromagnet and the plate. Thefrequency of input current to the electromagnet is same as the outputvibration frequency of the basket. The vibration amplitude of the basketis a function of the input current and frequency to the electromagnet,weight of the basket and processed material, and the stiffness of thesprings or resonators supporting the basket. Generally, as the inputcurrent to the electromagnet is increased, the vibration amplitudeincreases. As the input current to the electromagnet is decreased, thevibration amplitude decreases. In one aspect, the apparatuses 1240vibrate the basket 1230 at its natural resonant frequency.

Leaf springs or resonators 1250 are interconnected between the basket1230 and the support 1242 to allow the basket 1230 limited freedom ofmovement with respect to the electromagnetic apparatuses 1240.

A controller 1260 (shown schematically, which may be any suitable knownprogrammable logic controller (“PLC”), variable frequency drive (“VFD”)(one for each apparatus 1240), or controller for controllingelectromagnetic apparatuses and/or any controller or control systemdisclosed herein with suitable apparatus, devices, and programming forcontrolling the electromagnetic apparatuses) via lines 1262-1265 (shownschematically) controls the electromagnetic apparatuses 1240. In certainaspects the controller 1260 controls the frequency and amplitude ofvibrations of the basket 1230 by controlling the electromagneticapparatuses 1240. One or more accelerometers 1270 measure accelerationof the basket 1230 and provides signals via a cable 1266 (e.g. amulti-wire cable) to the controller 1260. In one aspect, theaccelerometer measures acceleration and sends an output signal to acontrol system or PLC. The control system or PLC includes parameters tocontrol the electromagnets. An acceleration setpoint is chosen andprogrammed into the PLC. If the accelerometer measures an accelerationbelow the setpoint, then the control system or PLC increases the inputcurrent to the electromagnets. If the accelerometer measures anacceleration above the setpoint, then the control system or PLCdecreases the input current to the electromagnets. If the accelerometermeasures an acceleration at the setpoint, then the control system or PLCmaintains the previous input current to the electromagnets. Thus, theshaker can operate at constant acceleration under load (and underchanging load) because of this closed-loop acceleration control, and, inone aspect, at a constant natural resonant frequency under load.

The system, in certain aspects, operates at the natural frequency of thebasket with load springs or resonators. Operating the shaker at thesystem resonance greatly reduces the input energy required to drive thesystem. Certain traditional shakers can operate at many times thenatural frequency and require excessive power to operate. Operating ashaker according to the present invention at its natural frequencyreduces energy requirements and permits the use of lighter baskets.

Certain traditional shakers operate at a fixed motor speed and with afixed rotating mass. This produces a fixed force at a fixed frequency. Abasket without the additional mass of drilling mud operates at a nominalacceleration. As drilling mud is added to the basket, the system mass isincreased, but the driving force remains fixed. This results in asignificantly decreased acceleration. Acceleration is a primary factordetermining shaker performance and fluid handling capacity. In order fora traditional shaker to be able to operate over a wide range of loads,some baskets have been designed to be exceptionally heavy compared tothe load they process. This helps reduce the effect of decreasingacceleration with increasing load. However, heavy baskets operatingabove the system natural frequency require significant input power. Evenwith heavy baskets, some traditional shakers can lose up to 25% of theirnominal acceleration with the addition of weighted drilling mud.

A shaker according to the present invention, in certain aspects, changesthe input frequency to the electromagnets to match the natural frequencyof the system. Thus, as more mass is added to the system with drillingmud, the PLC automatically determines the new lower natural frequency.In addition, in some aspects, the feedback from the accelerometer isused by the PLC to change the current to the electromagnet and maintaina constant acceleration amplitude. The electromagnets of the shaker canbe driven with a typical input current function and a superimposedhigh-frequency signal to partially de-plug the screens. This can also beaccomplished by out-of-phase driving with the typical input currentfunctions. Since adding weight to the screens changes the system naturalfrequency, this frequency can be measured to assist in determining theweight of the cuttings discharged by the shaker. A signal representativeof the natural frequency of the system is sent to the PLC and/orcomputer that calculates the total amount of solids discharged. In oneaspect, since the shaker is automatically tuned to the naturalfrequency, the mass (solids, liquid, plus any other material) can beindicated. The system natural frequency is calculated by taking thesquare root of (mass divided by stiffness) where the mass is the totalvibrating mass (screen or screens plus basket plus screen hardware plussolids plus liquid) and the stiffness is the equivalent spring rate ofthe resonators (e.g. four if four are used) in the vibration direction.Since the stiffness of the system does not change, any change in thenatural frequency when flow is introduced and when flow progress is dueto the addition of mass on a screen. When this is calculated for a lastor exit screen (at a discharge end of a shaker), it is assumed that mostof the mass on the screen is discharged and can be taken as anindication of solids discharged.

In one embodiments, the controller (PLC or computer) includes twocontrol loops. One control loop controls the acceleration by varying thevoltage supplied to the magnets and measuring the signal from theaccelerometer, indicative of the acceleration. The other control loopcontrols the frequency to maintain the lowest ratio of input power tooutput acceleration. To find the natural frequency of the system, thecontroller sweeps the magnet frequency over a given range that thenatural frequency is expected to lie within. The frequency that yieldsthe greatest acceleration for the same input is the natural frequency.The frequency control loop tried to maintain the frequency at thenatural frequency. Once the natural frequency is found, if the ratio ofinput power to output acceleration decreases, then the controlleradjusts down the frequency until the frequency is found that minimizesthe required input power to maintain the same acceleration.

It is within the scope of the present invention to provide a vibratoryseparator or shale shaker with one, two, or more electromagneticvibrators, the vibratory separator or shaker having one, two or moregenerally horizontal screens and/or one, two, three or more screensinclined uphill.

FIG. 44A shows schematically a shale shaker 1312 according to thepresent invention with a flow diffusion apparatus 1310. The flowdiffusion apparatus in FIG. 44A and those in FIG. 44B and FIG. 44C maybe any flow diffusion apparatus disclosed in U.S. Pat. No. 6,868,972.Fluid flowing from an exit end 1311 of an upper screen 1316 hits theflow diffusion apparatus 1310. Without the flow diffusion apparatus 1310in place, the fluid flowing from above would impact an area 1315 on alower screen 1320. A basket 1324 supports the screens. The flowdiffusion apparatus 1310 (as may be the case for any such apparatus) issecured to the basket 1324. The flow diffusion apparatus 1310 may beconnected to the upper screen, the lower screen, or both in addition to,or instead of, securement to the basket 1324. The flow diffusionapparatus 1310 has one or a series of holes 1318 therethrough whichpermit fluid to flow therethrough down onto the lower screen 1320.

A vibratory apparatus 1322 (shown schematically; any electromagneticvibratory apparatus disclosed herein) vibrates the basket 1324 in whichthe upper screen 1316 and lower screen 1320 are mounted. Fluid to betreated is introduced into a pool end 1326 of the shale shaker 1312.Fluid flows from both screens down into a collection receptacle 1328.Separated material exits from an exit end 1317 of the lower screen 1320.

FIG. 44B shows a shale shaker 1332 according to the present inventionwith a flow diffusion apparatus 1330. Fluid introduced at a fluidintroduction end 1334 of the shale shaker 1332 flows to an upper screen1336. The major portion of this fluid flows from the upper screen 1336to an intermediate screen 1340 and through the intermediate screen 1340to a lower screen 1342. Fluid flowing from an end 1344 of theintermediate screen 1340 (see arrow, FIG. 44B above the apparatus 1330)flows down onto the flow diffusion apparatus 1330 which, in theembodiment shown, is a solid plate; but which, according to the presentinvention, may have one or more holes, etc. for fluid flow therethrough.Vibrator apparatus 13322 (like that described above; shownschematically) vibrates a screen mounting basket 1346 in which thescreens are located.

FIG. 44C shows a shale shaker 1352 according to the present inventionwhich has a flow diffusion apparatus 1350 (like those described above)which is positioned below a fluid exit end 1354 of an upper screen 1356(which, as may be any screen etc. of any embodiment herein, may be anysuitable known screen(s), screen apparatus(es), or screen assembly orassemblies). Viewed on end the flow diffusion apparatus in one aspecthas two sides 1361, 1362 spaced apart by a flat part 1363 in a truncated“V” shape, but it is within the scope of this invention for any f lowdiffusion apparatus herein to be “V” shaped, “U” shaped, truncated “V”or “U” shaped, or flat. In one aspect side 1361 and/or side 1362 isdeleted.

Fluid flowing from the fluid exit end 1354 of the upper screen 1356falls into the flow diffusion apparatus 1350 and moves from there downonto a lower screen 1368 (which, as may be any screen etc. of anyembodiment herein, may be any suitable known screen(s), screen apparatus(es), or screen assembly or assemblies). In one aspect, fluid flow holes(of different diameters) are present in the flat part 1363 of the flowdiffusion apparatus 1350. In one aspect, all of the holes are of thesame diameter. In one aspect the flow diffusion apparatus 1350 extendsunder and corresponds in length to slightly less than the width of theupper screen 1356 above the flow diffusion apparatus 1350. Vibratorapparatus 1322 (shown schematically; like the apparatus 1322 describedabove) vibrates a screen mounting basket 1366 in which are secured thescreens 1356 and 1368.

A piezoelectric apparatus may be substituted for any electromagneticvibratory apparatus disclosed herein in any embodiment of the presentinvention, including, but not limited to, piezoelectric transducers andpatches as disclosed in U.S. Pat. Nos. 6,543,620; 6,938,778; and6,953,122; and in the references referred to in these patents—all ofsaid patents incorporated fully herein for all purposes. Incorporatedfully herein for all purposes is the U.S. patent application filed onOct. 20, 2005, Serial Number entitled “Shale Shakers and Screens withIdentification Apparatuses” co-owned with the present invention.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a computer readable medium containinginstructions that when executed by a computer implement a methodaccording to the present invention (any method disclosed hereinaccording to the present invention).

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a shale shaker having: a base; a basketmovably mounted on the base and for supporting screen apparatus fortreating material including fluid introduced into the vibratoryseparator; screen apparatus supported by the basket, the materialflowing onto the screen apparatus for treatment, fluid flowing throughthe screen apparatus for collection therebelow, at least a portion ofthe screen apparatus not inclined downhill; electromagnetic vibratoryapparatus connected to the basket for vibrating the basket and thescreen apparatus; driving apparatus for driving the electromagneticvibratory apparatus; and control apparatus for controlling theelectromagnetic vibratory apparatus.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a vibratory separator including: a base, abasket movably mounted on the base and for supporting screen apparatusfor treating material introduced to the vibratory separator, screenapparatus supported by the basket, the material flowing onto the screenapparatus for treatment, at least a portion of the screen apparatus notinclined downhill, electromagnetic vibratory apparatus connected to thebasket for vibrating the basket and the screen apparatus, drivingapparatus for driving the electromagnetic vibratory apparatus, andcontrol apparatus for controlling the driving apparatus and theelectromagnetic vibratory apparatus. Such a system may have one or some(in any possible combination) of the following: wherein at least aportion of the screen apparatus is inclined uphill; wherein at least aportion of the screen apparatus is horizontal; the screen apparatuscomprising at least one upper screen apparatus in the basket, the atleast one upper screen apparatus having a fluid exit end, and at leastone lower screen apparatus in the basket below the at least one upperscreen apparatus, fluid flowable from the at least one upper screenapparatus down onto the at least one lower screen apparatus, and flowdiffusion apparatus mounted below the fluid exit end of the at least oneupper screen apparatus and above the at least one lower screenapparatus, so that fluid flowing down from the at least one upper screenapparatus flows onto the flow diffusion apparatus and is diffusedthereby; wherein the vibratory separator is a shale shaker and thematerial is drilling fluid with drilled cuttings therein; wherein theelectromagnetic vibratory apparatus includes a metal plate spaced-apartfrom an electromagnet; the driving apparatus is variable frequency driveapparatus for selectively driving the electromagnetic vibratoryapparatus at a selected frequency, sensor apparatus connected to thevibratory separator for sensing a parameter indicative of operation ofthe vibratory separator for providing a signal corresponding to saidparameter, and the control apparatus for receiving signals from thesensor apparatus, for controlling the vibratory separator based on saidsignals; wherein the control apparatus is for automatically signallingthe variable frequency drive apparatus to change the frequency of theelectromagnetic vibratory apparatus so that force applied to the basketis changed; wherein the control apparatus can change the frequency tomaintain vibration of the basket at a natural resonant frequency of thebasket; wherein the control apparatus continuously changes the frequencyto continuously maintain the basket vibrating at the natural resonantfrequency of the basket; wherein the control apparatus controls thedriving apparatus to drive the electromagnetic vibratory apparatus tode-plug the screen apparatus; wherein the sensor apparatus comprises aplurality of sensor apparatuses; angle adjustment apparatus connected tothe basket for adjusting angle of the basket; flow sensor apparatusconnected to the vibratory separator for sensing the flow of materialonto the screen apparatus, the flow sensor apparatus controlled by andin communication with the control apparatus, and the control apparatusfor adjusting shaker operation in response to signals from the flowsensor apparatus; the electromagnetic vibratory apparatus connectible tothe basket at a plurality of locations so that a motion profile of thebasket is selectively variable between linear, elliptical, and circularmotion; wherein the motion profile of the basket includes a first shapeat a material introduction end of the basket and a second shape at amaterial exit end of the basket; wherein the basket has a middle areabetween the material introduction end and the fluid exit end and themotion profile of the basket includes a thin ellipse shape at thematerial introduction end, a medium ellipse shape at the middle area,and a fatter ellipse shape at the material exit end; the controlapparatus including interface apparatus for an interface between on-sitepersonnel at a location of the vibratory separator and an entity remotetherefrom; the vibratory separator on a drilling rig, the controlapparatus for monitoring and analyzing a plurality of signals from thesensor apparatus and for transmitting signals indicative of informationrelated to operation of the vibratory separator to a processor on thedrilling rig, the processor including a set of health check rules forhealth checks comprising logical rules, inputs and outputs for definingevents associated with the status of the vibratory separator, theprocessor for determining a severity code for each event and forreporting the events and severity codes to a central server, the eventsreported by the processor to the central server in a protocol defining adata structure, the data structure comprising a hierarchical tree nodestructure wherein results from application of the health check rules area bottommost node of the tree node structure, and displaying the eventseverity codes on a display; the processor for providing to the centralserver the results as records containing node information regarding anappropriate location for the results in the tree node structure; thecontrol apparatus running health checks in real time to provide resultsregarding on-going status of the vibratory separator; the controlapparatus for indicating a potential failure of the vibratory separator;the screen apparatus having an energizable identification apparatus,reader apparatus for reading the energizable identification apparatusand for sending a signal based on said reading to the control apparatus,and the control apparatus for automatically shutting down the vibratoryseparator upon receipt and processing of the signal based on theidentity of the screen apparatus; wherein the control apparatus canautomatically shut down the vibratory separator based on a parameter ofthe material or based on the flow rate of the material; energizableidentification apparatus on the electromagnetic vibratory apparatus foridentifying the vibratory apparatus; reader apparatus for reading theenergizable identification apparatus and for sending a signal based onsaid reading to the control apparatus; and/or wherein the basket is madeof composite material and the base is made of steel.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for treating material introducedto a vibratory separator, the method including introducing material to avibratory separator, the vibratory separator as any according to thepresent invention with electromagnetic vibratory apparatus, and controlapparatus for controlling driving apparatus that drives theelectromagnetic vibratory apparatus, treating the material in thevibratory separator, and controlling the electromagnetic vibratoryapparatus with the control apparatus. Such a method may have one or some(in any possible combination) of the following: wherein the vibratoryseparator includes angle adjustment apparatus connected to the basket,the method includes adjusting the angle of the basket with the angleadjustment apparatus; wherein the vibratory separator further includesdriving apparatus including variable frequency drive apparatus forselectively driving the electromagnetic vibratory apparatus at aselected frequency, sensor apparatus connected to the vibratoryseparator for sensing a parameter indicative of operation of thevibratory separator for providing a signal corresponding to saidparameter, and the control apparatus for receiving signals from thesensor apparatus, for controlling the vibratory separator based on saidsignals, the method further including controlling the variable frequencydrive apparatus with the control apparatus; wherein the controlapparatus is for automatically signalling the variable frequency driveapparatus to change the frequency of the electromagnetic vibratoryapparatus so that force applied to the basket is changed; wherein thebasket with material therein has a natural resonant frequency and thecontrol apparatus maintains said natural resonant frequency as materialflows through the basket; wherein the control apparatus controls thedriving apparatus to de-plug the screen apparatus; based on said naturalresonant frequency, determining a measure of solids discharged from thevibratory separator; and/or wherein the vibratory separator is a shaleshaker and the material is drilling fluid with solids therein.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a computer readable medium containinginstructions that when executed by a computer implement a method (anymethod according to the present invention) for treating materialintroduced to a vibratory separator or shale shaker.

In conclusion, therefore, the present invention and the embodimentsdisclosed herein and those covered by the appended claims are welladapted to carry out the objectives and obtain the ends set forth.Certain changes can be made in the subject matter without departing fromthe spirit and the scope of this invention. Changes are possible withinthe scope of this invention and each element or step recited in any ofthe following claims is to be understood as referring to all equivalentelements or steps. The following claims are intended to cover theinvention as broadly as legally possible in whatever form it may beutilized. The invention claimed herein is new and novel in accordancewith 35 U.S.C. § 102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35U.S.C. § 103 and satisfies the conditions for patentability in § 103.This specification and the claims that follow are in accordance with allof the requirements of 35 U.S.C. § 112.

1. A shale shaker comprising a base, a basket movably mounted on thebase and for supporting screen apparatus for treating material includingfluid introduced into the vibratory separator, screen apparatussupported by the basket, the material flowing onto the screen apparatusfor treatment, fluid flowing through the screen apparatus for collectiontherebelow, at least a portion of the screen apparatus not inclineddownhill, electromagnetic vibratory apparatus connected to the basketfor vibrating the basket and the screen apparatus, driving apparatus fordriving the electromagnetic vibratory apparatus, and control apparatusfor controlling the electromagnetic vibratory apparatus.
 2. A vibratoryseparator comprising a base, a basket movably mounted on the base andfor supporting screen apparatus for treating material introduced to thevibratory separator, screen apparatus supported by the basket, thematerial flowing onto the screen apparatus for treatment, at least aportion of the screen apparatus not inclined downhill, electromagneticvibratory apparatus connected to the basket for vibrating the basket andthe screen apparatus, driving apparatus for driving the electromagneticvibratory apparatus, and control apparatus for controlling the drivingapparatus and the electromagnetic vibratory apparatus.
 3. The vibratoryseparator of claim 2 wherein at least a portion of the screen apparatusis inclined uphill.
 4. The vibratory separator of claim 2 wherein atleast a portion of the screen apparatus is horizontal.
 5. The vibratoryseparator of claim 2 further comprising the screen apparatus comprisingat least one upper screen apparatus in the basket, the at least oneupper screen apparatus having a fluid exit end, and at least one lowerscreen apparatus in the basket below the at least one upper screenapparatus, fluid flowable from the at least one upper screen apparatusdown onto the at least one lower screen apparatus, and flow diffusionapparatus mounted below the fluid exit end of the at least one upperscreen apparatus and above the at least one lower screen apparatus, sothat fluid flowing down from the at least one upper screen apparatusflows onto the flow diffusion apparatus and is diffused thereby.
 6. Thevibratory separator of claim 2 wherein the vibratory separator is ashale shaker and the material is drilling fluid with drilled cuttingstherein.
 7. The vibratory separator of claim 5 wherein theelectromagnetic vibratory apparatus includes a metal plate spaced-apartfrom an electromagnet.
 8. The vibratory separator of claim 2 furthercomprising the driving apparatus comprising variable frequency driveapparatus for selectively driving the electromagnetic vibratoryapparatus at a selected frequency, sensor apparatus connected to thevibratory separator for sensing a parameter indicative of operation ofthe vibratory separator for providing a signal corresponding to saidparameter, and the control apparatus for receiving signals from thesensor apparatus, for controlling the vibratory separator based on saidsignals.
 9. The vibratory separator of claim 8 wherein the controlapparatus is for automatically signalling the variable frequency driveapparatus to change the frequency of the electromagnetic vibratoryapparatus so that force applied to the basket is changed.
 10. Thevibratory separator of claim 9 wherein the control apparatus can changethe frequency to maintain vibration of the basket at a natural resonantfrequency of the basket.
 11. The vibratory separator of claim 10 whereinthe control apparatus continuously changes the frequency to continuouslymaintain the basket vibrating at the natural resonant frequency of thebasket.
 12. The vibratory separator of claim 8 wherein the controlapparatus controls the driving apparatus to drive the electromagneticvibratory apparatus to de-plug the screen apparatus.
 13. The vibratoryseparator of claim 8 wherein the sensor apparatus comprises a pluralityof sensor apparatuses.
 14. The vibratory separator of claim 2 furthercomprising angle adjustment apparatus connected to the basket foradjusting angle of the basket.
 15. The vibratory separator of claim 2further comprising flow sensor apparatus connected to the vibratoryseparator for sensing the flow of material onto the screen apparatus,the flow sensor apparatus controlled by and in communication with thecontrol apparatus, and the control apparatus for adjusting shakeroperation in response to signals from the flow sensor apparatus.
 16. Thevibratory separator of claim 2 further comprising the electromagneticvibratory apparatus connectible to the basket at a plurality oflocations so that a motion profile of the basket is selectively variablebetween linear, elliptical, and circular motion.
 17. The vibratoryseparator of claim 16 wherein the motion profile of the basket includesa first shape at a material introduction end of the basket and a secondshape at a material exit end of the basket.
 18. The vibratory separatorof claim 16 wherein the basket has a middle area between the materialintroduction end and the fluid exit end and the motion profile of thebasket includes a thin ellipse shape at the material introduction end, amedium ellipse shape at the middle area, and a fatter ellipse shape atthe material exit end.
 19. The vibratory separator of claim 2 furthercomprising the control apparatus including interface apparatus for aninterface between on-site personnel at a location of the vibratoryseparator and an entity remote therefrom.
 20. The vibratory separator ofclaim 2 further comprising the vibratory separator on a drilling rig,the control apparatus for monitoring and analyzing a plurality ofsignals from the sensor apparatus and for transmitting signalsindicative of information related to operation of the vibratoryseparator to a processor on the drilling rig, the processor including aset of health check rules for health checks comprising logical rules,inputs and outputs for defining events associated with the status of thevibratory separator, the processor for determining a severity code foreach event and for reporting the events and severity codes to a centralserver, the events reported by the processor to the central server in aprotocol defining a data structure, the data structure comprising ahierarchical tree node structure wherein results from application of thehealth check rules are a bottommost node of the tree node structure, anddisplaying the event severity codes on a display.
 21. The vibratoryseparator of claim 20 further comprising the processor for providing tothe central server the results as records containing node informationregarding an appropriate location for the results in the tree nodestructure.
 22. The vibratory separator of claim 20 further comprisingthe control apparatus running health checks in real time to provideresults regarding on-going status of the vibratory separator.
 23. Thevibratory separator of claim 22 further comprising the control apparatusfor indicating a potential failure of the vibratory separator.
 24. Thevibratory separator of claim 2 further comprising the screen apparatushaving an energizable identification apparatus, reader apparatus forreading the energizable identification apparatus and for sending asignal based on said reading to the control apparatus, and the controlapparatus for automatically shutting down the vibratory separator uponreceipt and processing of the signal based on the identity of the screenapparatus.
 25. The vibratory separator of claim 24 wherein the controlapparatus can automatically shut down the vibratory separator based on aparameter of the material or based on the flow rate of the material. 26.The vibratory separator of claim 2 further comprising energizableidentification apparatus on the electromagnetic vibratory apparatus foridentifying the vibratory apparatus.
 27. The vibratory separator ofclaim 26 further comprising reader apparatus for reading the energizableidentification apparatus and for sending a signal based on said readingto the control apparatus.
 28. The vibratory separator of claim 1 whereinthe basket is made of composite material and the base is made of steel.29. A method for treating material introduced to a vibratory separator,the method comprising introducing material to a vibratory separator, thevibratory separator comprising a base, a basket movably mounted on thebase and for supporting screen apparatus for treating materialintroduced to the vibratory separator, screen apparatus supported by thebasket, the material flowing onto the screen apparatus for treatment, atleast a portion of the screen apparatus not inclined downhill,electromagnetic vibratory apparatus connected to the basket forvibrating the basket and the screen apparatus, driving apparatus fordriving the electromagnetic vibratory apparatus, and control apparatusfor controlling the driving apparatus and the electromagnetic vibratoryapparatus, treating the material in the vibratory separator, andcontrolling the electromagnetic vibratory apparatus with the controlapparatus.
 30. The method of claim 29 wherein the vibratory separatorincludes angle adjustment apparatus connected to the basket, the methodfurther comprising adjusting the angle of the basket with the angleadjustment apparatus.
 31. The method of claim 29 wherein the vibratoryseparator further includes the driving apparatus comprising variablefrequency drive apparatus for selectively driving the electromagneticvibratory apparatus at a selected frequency, sensor apparatus connectedto the vibratory separator for sensing a parameter indicative ofoperation of the vibratory separator for providing a signalcorresponding to said parameter, and the control apparatus for receivingsignals from the sensor apparatus, for controlling the vibratoryseparator based on said signals, the method further comprisingcontrolling the variable frequency drive apparatus with the controlapparatus.
 32. The method of claim 31 further comprising wherein thecontrol apparatus is for automatically signalling the variable frequencydrive apparatus to change the frequency of the electromagnetic vibratoryapparatus so that force applied to the basket is changed.
 33. The methodof claim 29 wherein the basket with material therein has a naturalresonant frequency and the control apparatus maintains said naturalresonant frequency as material flows through the basket.
 34. The methodof claim 29 wherein the control apparatus controls the driving apparatusto de-plug the screen apparatus.
 35. The method of claim 33 furthercomprising based on said natural resonant frequency, determining ameasure of solids discharged from the vibratory separator.
 36. Themethod of claim 30 wherein the vibratory separator is a shale shaker andthe material is drilling fluid with solids therein.
 37. A computerreadable medium containing instructions that when executed by a computerimplement a method for treating material introduced to a vibratoryseparator, the method including introducing material to a vibratoryseparator comprising a base, screen apparatus, a basket movably mountedon the base supporting screen apparatus for treating material introducedto the vibratory separator, the material flowing onto the screenapparatus, at least a portion of the screen apparatus not inclineddownhill, electromagnetic vibratory apparatus on the basket forvibrating the screen apparatus, driving apparatus for driving theelectromagnetic vibratory apparatus, and control apparatus, treating thematerial in the vibratory separator, and controlling the electromagneticvibratory apparatus and the driving apparatus with the controlapparatus.